International Journal of Extreme Manufacturing, Volume. 1, Issue 4, 45001(2019)

The interaction between grain boundary and tool geometry in nanocutting of a bi-crystal copper

Zhanfeng Wang1, Tao Sun1、*, Haijun Zhang2, Guo Li2, Zengqiang Li1, Junjie Zhang1, Yongda Yan1, and Alexander Hartmaier1,3
Author Affiliations
  • 1Center for Precision Engineering, Harbin Institute of Technology, Harbin 150001,China
  • 2Research Center of Laser Fusion, China Academy of Engineering Physics, Mianyang 621900,China
  • 3Interdisciplinary Centre for Advanced Materials Simulation, Ruhr-University Bochum, Bochum, 44780, Germany
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    Anisotropy is one central influencing factor on achievable ultimate machined surface integrity of metallic materials. Specifically, grain boundary has a strong impact on the deformation behaviour of polycrystalline materials and correlated material removal at the microscale. In the present work, we perform molecular dynamics simulations and experiments to elucidate the underlying grain boundaryassociated mechanisms and their correlations with machining results of a bi-crystal Cu under nanocutting using a Berkovich tool. Specifically, crystallographic orientations of simulated bi-crystal Cu with a misorientation angle of 44.1° are derived from electron backscatter diffraction characterization of utilized polycrystalline copper specimen. Simulation results reveal that blocking of dislocation motion at grain boundaries, absorption of dislocations by grain boundaries and dislocation nucleation from grain boundaries are operating deformation modes in nanocutting of the bi-crystal Cu. Furthermore, heterogeneous grain boundary-associated mechanisms in neighbouring grains lead to strong anisotropic machining behaviour in the vicinity of the grain boundary. Simulated machined surface morphology and machining force evolution in the vicinity of grain boundary qualitatively agree well with experimental results. It is also found that the geometry of Berkovich tool has a strong impact on grain boundary-associated mechanisms and resultant ploughing-induced surface pile-up phenomenon.

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    Zhanfeng Wang, Tao Sun, Haijun Zhang, Guo Li, Zengqiang Li, Junjie Zhang, Yongda Yan, Alexander Hartmaier. The interaction between grain boundary and tool geometry in nanocutting of a bi-crystal copper[J]. International Journal of Extreme Manufacturing, 2019, 1(4): 45001

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    Paper Information

    Received: Aug. 11, 2019

    Accepted: --

    Published Online: Jun. 4, 2020

    The Author Email: Sun Tao (taosun@hit.edu.cn and zhjj505@gmail.com)

    DOI:10.1088/2631-7990/ab4b68

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