Prediction Model of Cutting Force in Micro-milling Single Crystal Copper

To study the removal mechanism of materials during nano cutting, molecular dynamics method is adopted to simulate single crystal copper nanomachining processes, and subsurface defects evolvements and chip forming regulation are analyzed by revised centro-symmetry parameter method and the ratios of the tangential cutting forceand the normal cutting force. The results show that there are different defects under different cutting depths. When cutting depths is shallower, there are dislocation loop nucleation in the subsurface of the workpiece beneath the tool; however, when the cutting depths is deeper, there are dislocations nucleation and slipping along {101} plane and (111) plane. In addition, both tangential cutting forceand the normal cutting force decrease as the cutting depths decreasing. When the ratios of the normal cutting force and the tangential cutting force is below 0.9, the chip will be formed.

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Investigation of tool geometry in nanoscale cutting single-crystal copper by molecular dynamics simulation

Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology ◽

10.1177/1350650119826448 ◽

2019 ◽

Vol 233 (8) ◽

pp. 1208-1220 ◽

Cited By ~ 4

Author(s):

Houfu Dai ◽

Hao Du ◽

Jianbin Chen ◽

Genyu Chen

Keyword(s):

Molecular Dynamics ◽

Single Crystal ◽

Cutting Force ◽

Rake Angle ◽

Tool Geometry ◽

Single Crystal Copper ◽

Clearance Angle ◽

Edge Radius ◽

Lower Temperature ◽

Nanoscale Cutting

Molecular dynamics has been employed in this paper to investigate the nanoscale cutting process of single-crystal copper with a diamond tool. The behavior of the workpiece during material removal by diamond cutting has been studied. The effects of tool geometry including rake angle, clearance angle, and edge radius are thoroughly investigated in terms of chips, dislocation movement, temperature distribution, cutting temperature, cutting force, and friction coefficient. The investigation showed that an appropriate positive rake angle ([Formula: see text]), a suitable clearance angle ([Formula: see text]), or a smaller edge radius tip resulted in a smaller cutting force and a better subsurface finish. It was found that a tool with a rake angle of [Formula: see text] generated more chips, had a higher cutting efficiency, and produced a lower temperature in the workpiece, but a smaller rake angle tip was more conducive to protecting the groove compared to a large rake angle tip. Compared with a tool with a small clearance angle, the tool with a larger clearance angle generated more chips and caused a lower temperature rise in the copper workpiece, and prolonged its lifetime. In addition, a larger clearance angle tip was more conducive to protecting the groove. A smaller edge radius tip reduces the cutting heat during the nanoscale cutting process, while the volume of chips decreases. These results indicated that it is possible to control and adjust the tool parameters according to the tool rake angle, clearance angle, and edge radius during the machining of single-crystal copper, and a set of tool parameters were obtained: [Formula: see text] rake angle, [Formula: see text] clearance angle, and 0 nm edge radius which could reduce surface damage and the required cutting force.

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Simulation of a micro-milling single crystal copper process based on crystal plastic constitutive theory

SIMULATION ◽

10.1177/0037549720937051 ◽

2020 ◽

Vol 96 (12) ◽

pp. 957-968

Author(s):

Luan Yihan ◽

Meng Xiangyue ◽

Xue Liang ◽

Steven Y Liang ◽

Lu Xiaohong

Keyword(s):

Finite Element ◽

Single Crystal ◽

Simulation Model ◽

Finite Element Simulation ◽

Crystal Orientation ◽

Milling Process ◽

Micro Milling ◽

Work Piece ◽

Single Crystal Copper ◽

Element Simulation

The anisotropy of single crystal copper and crystal orientation have a significant effect on the micro-milling process. At present, there is no systematic and perfect theory to explain the influence of single crystal orientation on the micro-milling process. Therefore, it is urgent to conduct an in-depth study on the micro-milling process of single crystal copper. In this paper, based on the theory of crystal plasticity, considering the anisotropy of single crystal copper, the VUMAT material subroutine of single crystal copper is programmed by the Fortran language, and the crystal plastic constitution is introduced into the finite element simulation. The model of the micro-milling tool and work-piece is established and meshed. Considering the friction among the tool and the work-piece, material removal, etc., the three-dimensional finite element simulation model of single crystal copper micro-milling process is achieved by ABAQUS software. The validity of the simulation model of the micro-milling process of single crystal copper considering the single crystal plastic constitution is verified by experimental micro-milling forces. The research has explored a feasible way to predict the micro-milling force of single crystal copper, and has provided a reference for revealing the micro-milling mechanism of single crystal materials.

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A modified analytical cutting force prediction model under the tool flank wear effect in micro-milling nickel-based superalloy

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-017-0001-2 ◽

2017 ◽

Vol 91 (9-12) ◽

pp. 3709-3716 ◽

Cited By ~ 16

Author(s):

Xiaohong Lu ◽

Furui Wang ◽

Zhenyuan Jia ◽

Likun Si ◽

Chi Zhang ◽

...

Keyword(s):

Prediction Model ◽

Cutting Force ◽

Flank Wear ◽

Micro Milling ◽

Cutting Force Prediction ◽

Tool Flank Wear ◽

Force Prediction ◽

Nickel Based Superalloy

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The influence of different cutting speeds on the cutting force and strain–stress behaviors of single crystal copper during nano-scale orthogonal cutting

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2007.11.259 ◽

2008 ◽

Vol 201 (1-3) ◽

pp. 477-482 ◽

Cited By ~ 20

Author(s):

Zone-Ching Lin ◽

Jen-Ching Huang

Keyword(s):

Single Crystal ◽

Cutting Force ◽

Orthogonal Cutting ◽

Single Crystal Copper ◽

Nano Scale ◽

Strain Stress ◽

Stress Behaviors ◽

Cutting Speeds

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Comparison Analysis Between Simulation and Experiment of Cutting Force and Cutting Stress as Well as Chip Morphology During the Macro and Nano Cutting of Single Crystal Copper

10.21203/rs.3.rs-849526/v1 ◽

2021 ◽

Author(s):

Dongju Chen ◽

Shuiyuan Wu ◽

Yazhong He ◽

Shupei Li ◽

Yuchi Luo ◽

...

Keyword(s):

Single Crystal ◽

Cutting Force ◽

Cutting Forces ◽

Chip Morphology ◽

Cutting Process ◽

Dynamics Simulation ◽

Single Crystal Copper ◽

Simulation And Experiment ◽

Change Trend ◽

Cutting Model

Abstract In this paper, the simulation and experiment comparison of cutting force, cutting stress and chip morphology during the macro and nano cutting of single crystal copper are carried out. Firstly, a finite element method based on Johnson-Cook metal strength and failure model were used to establish a macro cutting model, and the cutting force, cutting stress, cutting displacement and chip morphology were obtained. Then a molecular dynamics simulation was used to establish a nano cutting model, and the cutting force, von mises stress and chip morphology were obtained. Afterwards, a comparative analysis of the two was carried out. Finally, the external turning experiment was used to verify the simulation results of the macro cutting model. The results show that: 1. The change trend of the cutting force in x and y directions are different,but the corresponding ratios of cutting forces in x and y directions in macro and nano cutting process are very close, and the corresponding ratios of the average macro and nano cutting forces in x and y directions are also very close. 2. The cutting stress in nano cutting process was about 100 times of macro cutting stress. 3. The chip length in macro cutting process is larger than the chip length in nano cutting process, and the shape is more regular. 4. The experimental cutting force change trend is very similar to the simulation cutting force change trend, but there exits difference in the value between the experiment cutting forces and simulated cutting forces.

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