Side Flow Effect on Surface Generation in Nano Cutting

Feifei Xu,Fengzhou Fang,Xiaodong Zhang

doi:10.1186/s11671-017-2136-3

Feifei Xu, Fengzhou Fang + Show 1 more

Open Access

https://doi.org/10.1186/s11671-017-2136-3

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Abstract

The side flow of material in nano cutting is one of the most important factors that deteriorate the machined surface quality. The effects of the crystallographic orientation, feed, and the cutting tool geometry, including tool edge radius, rake angle and inclination angle, on the side flow are investigated employing molecular dynamics simulation. The results show that the stagnation region is formed in front of tool edge and it is characterized by the stagnation radius Rs and stagnation height hs. The side flow is formed because the material at or under the stagnation region is extruded by the tool edge to flow to the side of the tool edge. Higher stagnation height would increase the size of the side flow. The anisotropic nature of the material which partly determines the stagnation region also influences the side flow due to the different deformation mechanism under the action of the tool edge. At different cutting directions, the size of the side flow has a great difference which would finally affect the machined surface quality. The cutting directions of {100} < 011>, {110} < 001>, and {110} < 1-10 > are beneficial to obtain a better surface quality with small side flow. Besides that, the side flow could be suppressed by reducing the feed and optimizing the cutting tool geometry. Cutting tool with small edge radius, large positive rake angle, and inclination angle would decrease the side flow and consequently improve the machined surface quality.

Highlights

Ultra-precision cutting is one of the most common methods in realizing the nanometric surface roughness and sub-micrometric form accuracy
The ever-reduced uncut chip thickness (UCT) making the material removal at nanoscale which is smaller than the material grain size causing the significant influence of the size effects [12] and material removal
The shape of the stagnation region could be approximate to an arc with the center locating at the center of tool nose and its radius denotes as Rs

Summary

Introduction

Ultra-precision cutting is one of the most common methods in realizing the nanometric surface roughness and sub-micrometric form accuracy. Based on the assumption that the workpiece material is removed ideally and the machined surface texture is the replication of tool nose profile, the surface roughness could attain nanometric even subnanometric scale, if decreasing the feed and increasing the tool nose radius. It always deviates from its ideal value due to many factors, such as, material properties of workpiece [1–4] and cutting tool geometry [5–7]. The influence of anisotropic nature of single crystal material on side flow has not been deeply investigated by far, which plays an important role in determining the machined surface quality

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