Numerical simulation of materials-oriented ultra-precision diamond cutting:review and outlook

Ultra-precision diamond cutting is a promising machining technique for realizing ultra-smooth surface of different kinds of materials.While fundamental understanding of the impact of workpiece material properties on cutting mechanisms is crucial for promoting the capability of the machining technique,numerical simulation methods at different length and time scales act as important supplements to experimental investigations.In this work,we present a compact review on recent advancements in the numerical simulations of material-oriented diamond cutting,in which representative machining phenomena are systematically summarized and discussed by multiscale simulations such as molecular dynamics simulation and finite element simulation:the anisotropy cutting behavior of polycrystalline material,the thermo-mechanical coupling tool-chip friction states,the synergetic cutting responses of individual phase in composite materials,and the impact of various external energetic fields on cutting processes.In particular,the novel physics-based numerical models,which involve the high precision constitutive law associated with heterogeneous deformation behavior,the thermo-mechanical coupling algorithm associated with tool-chip friction,the configurations of individual phases in line with real microstructural characteristics of composite materials,and the integration of external energetic fields into cutting models,are highlighted.Finally,insights into the future development of advanced numerical simulation techniques for diamond cutting of advanced structured materials are also provided.The aspects reported in this review present guidelines for the numerical simulations of ultra-precision mechanical machining responses for a variety of materials.

The interaction between grain boundary and tool geometry in nanocutting of a bi-crystal copper

Anisotropy is one central influencing factor on achievable ultimate machined surface integrity of metallic materials.Specifically,grain boundary has a strong impact on the deformation behaviour of polycrystalline materials and correlated material removal at the microscale.In the present work,we perform molecular dynamics simulations and experiments to elucidate the underlying grain boundaryassociated mechanisms and their correlations with machining results of a bi-crystal Cu under nanocutting using a Berkovich tool.Specifically,crystallographic orientations of simulated bi-crystal Cu with a misorientation angle of 44.1°are derived from electron backscatter diffraction characterization of utilized polycrystalline copper specimen.Simulation results reveal that blocking of dislocation motion at grain boundaries,absorption of dislocations by grain boundaries and dislocation nucleation from grain boundaries are operating deformation modes in nanocutting of the bi-crystal Cu.Furthermore,heterogeneous grain boundary-associated mechanisms in neighbouring grains lead to strong anisotropic machining behaviour in the vicinity of the grain boundary.Simulated machined surface morphology and machining force evolution in the vicinity of grain boundary qualitatively agree well with experimental results.It is also found that the geometry of Berkovich tool has a strong impact on grain boundary-associated mechanisms and resultant ploughing-induced surface pile-up phenomenon.

Plastic deformation modelling of tempered martensite steel block structure by a nonlocal crystal plasticity model

The plastic deformations of tempered martensite steel representative volume elements with different martensite block structures have been investi- gated by using a nonlocal crystal plasticity model which considers isotropic and kinematic hardening produced by plastic strain gradients. It was found that pro- nounced strain gradients occur in the grain boundary region even under homo- geneous loading. The isotropic hardening of strain gradients strongly influences the global stress-strain diagram while the kinematic hardening of strain gradi- ents influences the local deformation behaviour. It is found that the additional strain gradient hardening is not only dependent on the block width but also on the misorientations or the deformation incompatibilities in adjacent blocks.

Cutting path-dependent machinability of SiCp/Al composite under multi-step ultra-precision diamond cutting

Particle-tool interactions,which govern the synergetic deformation of SiC particle reinforced Al matrix composites under mechanical machining,strongly depend on the geometry of particle position residing on cutting path.In the present work,we investigate the influence of cutting path on the machinability of a SiCp/Al composite in multi-step ultra-precision diamond cutting by combining finite element simulations with experimental observations and characterization.Be consistent with experimentally characterized microstructures,the simulated SiCp/Al composite is considered to be composed of randomly distributed polygonally-shaped SiC particles with a volume fraction of 25 vol%.A multi-step cutting strategy with depths of cut ranging from 2 to 10 lm is adopted to achieve an ultimate depth of cut of 10 lm.Intrinsic material parameters and extrinsic cutting conditions utilized in finite element simulations of SiCp/Al cutting are consistent with those used in corresponding experiments.Simulation results reveal different particle-tool interactions and failure modes of SiC particles,as well as their correlations with machining force evolution,residual stress distribution and machined surface topography.A detailed comparison between numerical simulation results and experimental data of multi-step diamond cutting of SiCp/Al composite reveals a substantial impact of the number of cutting steps on particle-tool interactions and machined surface quality.These findings provide guidelines for achieving high surface finish of SiCp/Al composites by ultra-precision diamond cutting.

Anisotropy-Related Machining Characteristics in Ultra-Precision Diamond Cutting of Crystalline Copper

Deformation behavior at grain levels greatly affects the machining characteristics of crystalline materials.In the present work,we investigate the influence of material anisotropy on ultra-precision diamond cutting of single crystalline and polycrystalline copper by experiments and crystal plasticity finite element simulations.Specifically,diamond turning and in situ SEM orthogonal cutting experiments are carried out to provide direct experimental evidence of the material anisotropy-dependent cutting results in terms of machined surface morphology and chip profile.Corresponding numerical simulations with the analysis of built stress further validate experimental results and reveal the mechanisms governing the material anisotropy influence.The above findings provide insight into the fabrication of ultra-smooth surfaces of polycrystalline metals by ultraprecision diamond turning.