Modeling and simulation of the tool wear in nanometric cutting

Abstract

Tool wear is a significant factor affecting the machined surface quality. In this paper, a molecular dynamics (MD) simulation approach is proposed to model the wear of the diamond tool in nanometric cutting. It includes the effects of the cutting heat on the workpiece property. MD simulation is carried out to simulate the nanometric cutting of a single crystal silicon plate with the diamond tip of an atomic force microscope (AFM). The wear mechanism is investigated by the calculation of the temperature, the stress in the diamond tip, and the analysis of the relationship between the temperature and sublimation energy of the diamond atoms and silicon atoms. Microstrength is used to characterize the wear resistance of the diamond tool. The machining trials on an AFM are performed to validate the results of the MD simulation. The results of MD simulation and AFM experiments all show that the thermo-chemical wear is the basic wear mechanism of the diamond cutting tool.