Simulation and Experiments of Material-Oriented Ultra-Precision Machining

310 Pages·2019·21.072 MB·English

by  Junjie Zhang, Bing Guo, Jianguo Zhang

Springer Tracts in Mechanical Engineering
Junjie Zhang
Bing Guo
Jianguo Zhang Editors
Simulation and
Experiments of
Material-Oriented
Ultra-Precision
Machining
Springer Tracts in Mechanical Engineering
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Seung-Bok Choi, College of Engineering, Inha University, Incheon, South Korea
Haibin Duan, Beijing University of Aeronautics and Astronautics, Beijing,
P.R. China
Yili Fu, Harbin Institute of Technology, Harbin, P.R. China
Carlos Guardiola, CMT-Motores Termicos, Universitat Politècnica de València,
València, Spain
Jian-Qiao Sun, University of California, Merced, CA, USA
Young W. Kwon, Naval Postgraduate School, Monterey, CA, USA
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Junjie Zhang Bing Guo
(cid:129)
Jianguo Zhang
Editors
Simulation and Experiments
of Material-Oriented
Ultra-Precision Machining
123
Editors
Junjie Zhang Jianguo Zhang
Centerfor Precision Engineering Schoolof MechanicalScience
Harbin Institute of Technology andEngineering
Harbin, Heilongjiang, China HuazhongUniversity of Science
andTechnology
BingGuo Wuhan, China
Schoolof Mechatronics Engineering
Harbin Institute of Technology
Harbin, Heilongjiang, China
ISSN 2195-9862 ISSN 2195-9870 (electronic)
SpringerTracts inMechanical Engineering
ISBN978-981-13-3334-7 ISBN978-981-13-3335-4 (eBook)
https://doi.org/10.1007/978-981-13-3335-4
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Contents
Fundamentals of Nanometric Cutting of Nanotwinned Copper . . . . . . . 1
Junjie Zhang, Yongda Yan and Tao Sun
Investigation into Plastic Deformation and Machining-Induced
Subsurface Damage of High-Entropy Alloys . . . . . . . . . . . . . . . . . . . . . 23
Jia Li and Qihong Fang
Investigation into the Realization of a Single Atomic Layer Removal
in Nanoscale Mechanical Machining of Single Crystalline Copper. . . . . 53
Pengzhe Zhu and Jianyong Li
Thermally Assisted Microcutting of Calcium Fluoride
Single Crystals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Yan Jin Lee, Akshay Chaudhari, Jiong Zhang and Hao Wang
Cutting Mechanism and Surface Formation of Ultra-Precision
Raster Fly Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Guoqing Zhang and Suet To
Modeling and Experimental Study of Surfaces Optoelectronic
Elements from Crystal Materials in Polishing . . . . . . . . . . . . . . . . . . . . 129
Yu. D. Filatov
Advanced Applications of Elliptical Vibration Cutting
in Micro/Nanomachining of Difficult-to-Cut Materials . . . . . . . . . . . . . . 167
Jianguo Zhang, Norikazu Suzuki and Eiji Shamoto
Ultra-precision Machining of Hard and Brittle Materials
with Coarse-Grained Grinding Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . 201
Bing Guo and Qingliang Zhao
Technology Precision Machining of Ceramic Balls in the V-Grooves
of Variable Curvature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Oleg Pasichnyi
v
vi Contents
The Contribution of Ion Plasma Sprayed Coating to Performance
of Precision Diamond Dressing Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . 265
V. Lavrinenko and M. Sheiko
Nitrogen-Vacancy Color Centers in Diamond Fabricated by Ultrafast
Laser Nanomachining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Changkun Shi, Huihui Luo, Zongwei Xu and Fengzhou Fang
Fundamentals of Nanometric Cutting
of Nanotwinned Copper
JunjieZhang,YongdaYanandTaoSun
Abstract Nanotwinned (NT) Cu containing a high density of growth twin
boundaries (TBs) is one emerging precious metal for its extraordinary properties
ofhighstrength,intermediateductility,andhighelectricconductivity.Inthepresent
work,weelucidatethedeformationmechanismsofnanotwinnedCusubjectedtothe
diamond cutting-based nanometric cutting by means of molecular dynamics sim-
ulations, with an emphasis on examining the influence of intrinsic microstructural
parametersandextrinsicmachiningparameteronthenanometriccuttingprocesses.
Theunderlyingdeformationmechanismsofthematerialsarefurthercorrelatedwith
theevolutionofmachiningforcesandtheformationofmachinedsurfaceandchips.
Our simulation results indicate that dislocation slip, dislocation–TBs interactions,
and TBs-associated mechanisms work in parallel in the plastic deformation of the
NTCu.Inparticular,dislocation–TBinteractionsandTBs-associatedmechanisms
arestronglydependentonrakeangleofcuttingtool,TBinclinationangle,TBspac-
ing,andgrainsize,whichleadstostronganisotropiccuttingresponseofNTCuthat
originatesfromtheheterogeneouslocalizeddeformation.
1 Introduction
Aninterfaceisacommonboundaryseparatingtwodifferentphasesand/orcrystals
of different chemical compositions and/or crystallographic misorientations. Inter-
faceshaveastrongimpactonthechemical,physical,andmechanicalpropertiesof
materialsparticularlywithhighsurface-to-volumeratio,duetothechemicaland/or
crystallographicdiscontinuity.Furthermore,theimpactofGBsisheavilyinfluenced
bythestructuraltypeofGBs.Forinstance,whilenanocrystallinemetalswithaver-
agegrainsizesdownintothenanometerregimearestrongbutbrittleduetoseverely
confined space for dislocation motion, the introduction of aligned coherent twin
boundaries(TBs)leadstoasuperiorcombinationofultra-highstrengthandinterme-
B
J.Zhang( )·Y.Yan·T.Sun
CenterforPrecisionEngineering,HarbinInstituteofTechnology,Harbin150001,China
e-mail:[email protected]
©SpringerNatureSingaporePteLtd.2019 1
J.Zhangetal.(eds.),SimulationandExperimentsofMaterial-Oriented
Ultra-PrecisionMachining,SpringerTractsinMechanicalEngineering,
https://doi.org/10.1007/978-981-13-3335-4_1
2 J.Zhangetal.
diateductilityinNTmetals.ThehighstrengthofNTmetalsisaresultofTBsacting
aseffectiveobstaclestodislocationmotion,whiletheeminentductilityisowingto
theenhanceddislocationnucleationsitesprovidedbyTBs[1,2].TheNTmetalsthus
have become emerging precious metals for the fabrication of advanced functional
nanostructuresforitsextraordinarymechanicalproperties.
Thediamondcutting-basednanometriccuttingisoneprominenttechniqueforthe
fabricationofultra-smoothsurfaceaswellasprecisesurfacemicro-/nanostructures
foritsnanometer-scalemachiningaccuracyandshapeaccuracy[3,4].Tofacilitate
thedevelopmentofnanometriccuttingtechnique,afundamentalunderstandingofthe
nanometriccuttingmechanismsatthenanometerscaleisessentiallyrequired.Since
thetooledgeradiusiscomparablewithdepthofcutinthediamondcuttingprocess,
the properties of workpiece material play an important even dominant role in the
cuttingprocess,whichintroducesgreatchallengesinelucidatingmechanismsofNT
metalsforitscomplexdeformationbehavior.TB-associatedmechanismsalsoplayan
importantroleintheplasticdeformationofNTmetals,inadditiontodislocationslip
thatdominatesintragrainplasticity.Specifically,dislocation–TBinteractionsinterms
ofblocking,accommodationandtransition,aswellasTBmigrationanddetwinning,
are common deformation modes of NT metals under external loads [5–10]. More
recently, Wang et al. presented direct evidence of interaction of dislocation with a
singlenanotwinbyperforminginsitunanoindentation[11].Althoughdeformation
behaviors of NT metals under tension, torsion, compression, nanoindentation, and
frictionhavebeenreportedinenormousliterature,thedislocation–TBinteractions,
particularlyitsroleindeterminingthematerialremovalandevolutionofmachining
forceinnanometriccuttingofNTmetals,arelargelyunknown.
AtypicalcuttingrouteonNTmetalsinvolvesmultiplegrains,whichareofdiffer-
entcrystallographicorientationsaswellastheinclinationanglesofalignedTBswith
respecttothesurface.Specifically,theinclinationangleisalsoofgreatimportancein
understandingofthenanometriccuttingmechanismsofNTCu,asinclinedinternal
twin planes with varying Schmid’s factors possess distinguishable dislocation–TB
interactions.Stukowskietal.[12]reportedthattheinclinationofdislocationtoTBsis
stronglydependentonSchmid’sfactorsofindividualgrains.Brownetal.[13]showed
thattheplacementofTBorientationwithrespecttotheloadingaxisgreatlyaffectsthe
plasticityreversibilityofNTCu.Furthermore,Weietal.demonstratedthattheplastic
deformationofNTCunanowirescanbegovernedpurelybyTBmigrationthrough
designingtheinclinationangleofTBs[14].Jangetal.reporteddetwinning-governed
plasticityinNTnanopillarscontaininginclinedTBs[15].Zhangetal.demonstrated
thattheanisotropicfrictionalresponseofNTCuoriginatesfromtheheterogeneous
localizeddeformation,whichisstronglyinfluencedbycrystallographicorientation,
twin boundary orientation, and loading condition [16]. Therefore, it is intriguing
to explore the effect of inclination angle on the nanometric cutting of NT Cu. It
hasbeen demonstrated thattheTB-relatedimpactonthemechanical propertiesof
NT metals is strongly dependent on the intrinsic sizes of internal microstructures.
Recentexperimentaltestsandatomisticsimulationshaveshownthatthestrengthof
NTCuhasastrongdependenceonTBspacing.Specifically,thestrengthofNTCu
firstincreaseswithdecreasingTBspacinginaHall–Petchmanner.However,after
FundamentalsofNanometricCuttingofNanotwinnedCopper 3
reachingthemaximumstrengthatthecriticalTBspacing,strengthsofteningoccurs
whenTBsfurtherdecrease[17].Inaddition,itisfoundthatthecriticalTBspacing
depends on grain size; i.e., the smaller the grain size, the smaller the critical twin
thickness[2].Therefore,itisalsointriguingtostudytheeffectofTBspacingand
grainsizeonthenanometriccuttingofNTmetals.
Inlightofthesefindingsreportedintheliterature,inthepresentworkweperform
MDsimulationstoinvestigatethenanometriccuttingofNTCuusingthediamond
cuttingtool.Theinfluenceofrakeangle,inclinationangleofTBs,TBspacing,and
grain size on the nanometric cutting in terms of elastic and plastic deformation of
thematerial,variationsofmachiningforce,machinedsurfacequality,andchipfor-
mation is further studied. Without loss of physics, we first consider single NT Cu
samplesintheabsenceofgrainboundaries(GBs)butcontainingtwinplanesthatare
parallel,inclined,andperpendiculartothefreesurface.Tocharacterizetheeffectof
cuttingtoolgeometry,weperformnanometriccuttingsimulationsonthesameNT
Cu sample containing 26° inclined TBs with respect to the free surface using dia-
mondcuttingtoolwiththreedifferentrakeangles,whichshowsthattherakeangle
of45°resultsinsmallerenergydissipationandbettermachinedsurfacequalitythan
the other two rake angles of 0° and −45°. Then with the optimized rake angle of
45°,weaddresstheeffectofinclinationangleofTBsbyperformingcuttingalong
thesamescratchingdirectionbutondifferentsurfaceswithvariedinclinationangles
of the TBs cutting the surfaces. We found an inclination angle of 0° for the best
machinedsurfacequality.MorepracticalpolycrystallineNTCuisthensimulated,
inwhichtheeffectsoftwinspacingandgrainsizeonthecuttingprocessesarestud-
ied.The transitionin deformation mechanisms, the evolution of cutting force, and
the cutting-induced microstructure change are closely investigated. Based on such
atomisticsimulations,wedemonstratethatcuttingofNTCuexhibitsstronghetero-
geneouscharacteristic,originatingfromthestrongcompetitionbetweenindividual
deformationmechanisms.Thechapterisorganizedasfollows:InSect.2,wedescribe
detailsaboutthemodelsofNTCusamples,thenanoscratchingprocedure,andthe
utilizeddefectanalysisandvisualizationtechniques.Theresultsofnanometriccut-
ting of NT Cu with emphasis on the aspects of rake angle, inclination angle, TB
spacing,andgrainsizearethenpresentedanddiscussedinSect.3.Finally,inSect.4
wesummarizetheresults.
2 SimulationMethod
The utilized MD model of nanometric cutting of NT Cu is composed of a NT Cu
substrate and a diamond cutting tool, as shown in Fig. 1. The common neighbor
analysis(CNA)[18]isutilizedtoidentifytypesoflatticedefects,andthecoloring
scheme is as follows: Blue stands for face-centered cubic (FCC) atoms, red for
hexagonal close-packed (HCP) atoms, and gray for other atoms including surface
atoms and dislocation cores. A single HCP-coordinated layer identifies a coherent