Abstract
Single grit scratching is a basic form of material removal for many processes, such as grinding single point diamond turning and coating bonding performance tests. It has been widely used in the study of micro-scale and nano-scale material removal mechanisms. In this study, single grit linearly loading scratching tests were carried out on a scratching tester. A Rockwell indenter made of natural diamond was selected as the tool used, and the material of the workpiece was oxygen-free copper. Scratch topography was measured using a super-depth microscope to analyze the material deformation of the scratching process. A single grit scratching simulation has been developed by AdvantEdge™ to comprehensively study the material deformation of scratching processes. A material constitutive model and friction model were acquired using a quasi-static uniaxial compression experiment and a reciprocating friction test, respectively. These two models were used as the input models in the finite simulations. The simulated scratching forces aligned well with the experimental scratching forces, which verified the precision of the simulation model. Since only the scratching force could be obtained in the scratching experiment, the plastic strain, material flow, and residual stress of the scratching were further analyzed using simulations. The results showed that the plastic strain of the workpiece increased with the increase in scratching depth, and further analysis showed that the workpiece surface was distributed with residual compressive stress and the sub-surface was distributed with residual tensile stress in single grit scratching.
Highlights
The single grit scratching test is used to study complex loading conditions in a controlled manner and is widely used in the study of tribology, bonding force, and workpiece material removal mechanisms
Looijmans et al used a single grit of diamond to scratch isotactic polypropylene
F Cao et al studied the wear resistance of TiAlSiN coatings using single grit scratching with variable loading [6]
Summary
The single grit scratching test is used to study complex loading conditions in a controlled manner and is widely used in the study of tribology, bonding force, and workpiece material removal mechanisms. Xu et al studied the material removal mechanism of micro-cracks and crack propagation by scratching aluminum oxide with a single grit [9]. Finite element simulation is increasingly used to study the problems which cannot be measured in experiments. They can visualize complex deformation fields, such as stress and strain distributions. The simulation results included data that cannot be measured during the actual machining experiments, such as the flow of materials, the distribution of the strain field, and the distribution of the residual stress field. Analyzing simulation data can better explain material removal mechanisms during the scratching process
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