An analytical method for assessing the initiation and interaction of cracks in fused silica subjected to contact sliding

Understanding the fracture behavior of fused silica in contact sliding is important to the fabrication of damage-free optics.This study develops an analytical method to characterize the stress field in fused silica under contact sliding by extending the embedded center of dilation(ECD)model and considering the depth of yield region.The effects of densification on the stress fields were considered by scratch volume analysis and finite element analysis.Key mechanisms,such as crack initiation and morphology evolution were comprehensively investigated by analyzing the predicted stress fields and principal stress trajectories.The predictions were validated by Berkovich scratching experiment.It was found that partial conical,median and lateral cracks could emerge in the loading stage of the contact sliding,but radial and lateral cracks could be initiated during unloading.It was also found that the partial conical crack had the lowest initiation load.The intersection of long lateral cracks makes the material removal greater.

Ultrasonic vibration-assisted machining:principle,design and application

Ultrasonic vibration-assisted （UVA） machining is a process which makes use of a micro-scale high frequency vibration applied to a cutting tool to improve the material removal effectiveness. Its principle is to make the tool-workpiece interaction a microscopically non-monotonic process to facilitate chip separation and to reduce machining forces. It can also reduce the deformation zone in a workpiece under machining, thereby improving the surface integrity of a component machined. There are several types of UVA machining processes, differentiated by the directions of the vibrations introduced relative to the cutting direction. Applications of UVA machining to a wide range of workpiece materials have shown that the process can considerably improve machining performance. This paper aims to provide a comprehensive discussion and review about some key aspects of UVA machining such as cutting kinematics and dynamics, effect of workpiece materials and wear of cutting tools, involving a wide range of workpiece materials including metal alloys, ceramics, amorphous and composite materials. Some aspects for further investigation are also outlined at the end.

Particle fracture and debonding during orthogonal machining of metal matrix composites

This paper investigates the particle fracture and debonding during machining of metal matrix composite （MMC） due to developed stress and strain, and interaction with moving tool by finite element analysis. The machining zone was divided into three regions： primary, secondary and tertiary deformation zones. The tendency of particles to fracture in each deformation zone was investigated. The findings of this study were also discussed with respect to the experimental results available in the literature. It was found that particles at the cutting path inthe tertiary deformation zone fractured as it interacted with tool. In the secondary deformation zone, particles interacted with other particles as well as cutting tool. This caused debonding and fracture of huge number of particles as those were moving up along the rake face with the chips. No particle fracture was noted at the primary deformation zone. The results obtained from finite element analysis were very similar to those obtained from experimental studies.

Investigation into the room temperature creep-deformation of potassium dihydrogen phosphate crystals using nanoindentation

It has been a tremendous challenge to manu facture damage-free and smooth surfaces of potassium dihydrogen phosphate (KDP) crystals to meet the require ments of high-energy laser systems. The intrinsic issue is whether a KDP crystal can be plastically deformed so that the material can be removed in a ductile mode during the machining of KDP. This study investigates the room tem perature creep-deformation of KDP crystals with the aid of nanoindentation. A stress analysis was carried out to identify the creep mechanism. The results showed that KDP crystals could be plastically deformed at the nanoscale. Dislocation motion is responsible for creep-deformation. Both creep rate and creep depth decrease with decrease in peak force and loading rate. Dislocation nucleation and propagation bring about pop-ins in the load displacement curves during nanoindentation.

Nano-machining of materials： understanding the process through molecular dynamics simulation

Molecular dynamics （MD） simulation has been widely applied in various complex, dynamic processes at atomistic scale, because an MD simulation can provide some deformation details of materials in nano-processing and thus help to investigate the critical and important issues which cannot be fully revealed by experiments. Extensive research with the aid of MD simulation has provided insights for the development of nanotechnology. This paper reviews the fundamentals of nano-machining from the aspect of material structural effects, such as single crystalline, polycrystalline and amorphous materials. The classic MD simulations of nano-indentation and nano-cutting which have aimed to investigate the machining mechanism are discussed with respect to the effects of tool geometry, material properties and machining parameters. On nano-milling, the discussion focuses on the understanding of the grooving quality in relation to milling conditions.

Debris effect on the surface wear and damage evolution of counterpart materials subjected to contact sliding

This paper aims to explore the debris effect on surface wear and damage evolution of counterpart materials during contact sliding.A cylinder-on-flat testing configuration is used to investigate the wear behaviours of the contact pair.To explore the roles of wear debris,compressed air is applied to remove the debris in sliding zones.The comparative study demonstrates that the influence of debris removal is related to the surface properties of contact pairs.When substantial wear debris accumulates on the tool surface,debris removal can considerably alter surface damage evolution,resulting in different friction transitions,distinct surface morphology of contact pair,as well as different rates of material removal.It has been found that the surface damage evolution will not reach a stable stage unless the increase of wear particle number ceases or the average size of wear particles becomes lower than a specific threshold.However,the influence of debris removal reduces when the adhesion between the contact pair materials gets smaller.

Material removal mechanisms and characteristics of potassium dihydrogen phosphate crystals under nanoscratching

Potassium dihydrogen phosphate(KDP)crystals are important materials in high-energy laser systems.However,because these crystals are brittle and soft,machining-induced defects often emerge in KDP components.This study aimed to investigate the material removal mechanisms and characteristics of KDP during nanoscratching using Berkovich,spherical,and conical indenters.We found that KDP surface layers could be removed in a ductile mode at the micro/nanoscale and that dislocation motion was one of the main removal mechanisms.Removal characteristics are related to the stress fields generated by indenter geometries.The spherical indenter achieved a ductile removal mode more easily.The lateral force of nanoscratching increased with an increase in the normal force.The coefficient of friction(COF)followed the same trend as the lateral force when spherical and conical indenters were used.However,the COF was independent of the normal force when using a Berkovich indenter.We found that these COF variations could be accurately described by friction models.

Elastic-plastic-brittle transitions of potassium dihydrogen phosphate crystals:characterization by nanoindentation

Potassium dihydrogen phosphate(KDP)crystals are widely used in laser ignition facilities as optical switching and frequency conversion components.These crystals are soft,brittle,and sensitive to external conditions(e.g.,humidity,temperature,and applied stress).Hence,conventional characterization methods,such as transmission electron microscopy,cannot be used to study the mechanisms of material deformation.Nevertheless,understanding the mechanism of plastic-brittle transition in KDP crystals is important to prevent the fracture damage during the machining process.This study explores the plastic deformation and brittle fracture mechanisms of KDP crystals through nanoindentation experiments and theoretical calculations.The results show that dislocation nucleation and propagation are the main mechanisms of plastic deformation in KDP crystals,and dislocation pileup leads to brittle fracture during nanoindentation.Nanoindentation experiments using various indenters indicate that the external stress fields influence the plastic deformation of KDP crystals,and plastic deformation and brittle fracture are related to the material's anisotropy.However,the E l Ning Hou 13b908074@hit.edu.cn Liang-Chi Zhang liangchi.zhang@unsw.edu.au 1 School of Mechatronics Engineering,Harbin Institute of Technology,Harbin 150001,People's Republic of China 2 School of Mechatronics Engineering,Shenyang Aerospace University,Shenyang 110136.People's Republic of China'Laboratory for Precision and Nano Processing Technologies,School of Mechanical and Manufacturing Engineering,The University of New South Wales,Sydney,NSW 2052,Australia effect of loading rate on the KDP crystal deformation is practically negligible.The results of this research provide important information on reducing machining-induced damage and further improving the optical performance of KDP crystal components.

Understanding the formation mechanism of subsurface damage in potassium dihydrogen phosphate crystals during ultraprecision fly cutting

Potassium dihydrogen phosphate(KDP)crystals play an important role in high-energy laser systems,but the laser damage threshold(LDT)of KDP components is lower than expected.The LDT is significantly influenced by subsurface damage produced in KDP crystals.However,it is very challenging to detect the subsurface damage caused by processing because a KDP is soft,brittle,and sensitive to the external environment(e.g.,humidity,temperature and applied stress).Conventional characterization methods such as transmission electron microscopy are ineffective for this purpose.This paper proposes a nondestructive detection method called grazing incidence X-ray diffraction(GIXD)to investigate the formation of subsurface damage during ultra-precision fly cutting of KDP crystals.Some crystal planes,namely(200),(112),(312),(211),(220),(202),(301),(213),(310)and(303),were detected in the processed subsurface with the aid of GIXD,which provided very different results for KDP crystal bulk.These results mean that single KDP crystals change into a lattice misalignment structure(LMS)due to mechanical stress in the subsurface.These crystal planes match the slip systems of the KDP crystals,implying that dislocations nucleate and propagate along slip systems to result in the formation of the LMS under shear and compression stresses.The discovery of the LMS in the subsurface provides a new insight into the nature of the laser-induced damage of KDP crystals.

A data-driven approach to RUL prediction of tools

An effective and reliable prediction of the remaining useful life(RUL)of a tool is important to a metal forming process because it can significantly reduce unexpected maintenance,avoid machine shutdowns and increase system stability.This study proposes a new data-driven approach to the RUL prediction for metal forming processes under multiple contact sliding conditions.The data-driven approach took advantage of bidirectional long short-term memory(BLSTM)and convolutional neural networks(CNN).A pre-trained lightweight CNN-based network,WearNet,was re-trained to classify the wear states of workpiece surfaces with a high accuracy,then the classification results were passed into a BLSTM-based regression model as inputs for RUL estimation.The experimental results demonstrated that this approach was able to predict the RUL values with a small error(below 5%)and a low root mean square error(RMSE)(around 1.5),which was more superior and robust than the other state-of-the-art methods.