Anisotropy-Related Machining Characteristics in Ultra-Precision Diamond Cutting of Crystalline Copper

Deformation behavior at grain levels greatly affects the machining characteristics of crystalline materials. In the present work, we investigate the influence of material anisotropy on ultra-precision diamond cutting of single crystalline and polycrystalline copper by experiments and crystal plasticity finite element simulations. Specifically, diamond turning and in situ SEM orthogonal cutting experiments are carried out to provide direct experimental evidence of the material anisotropy-dependent cutting results in terms of machined surface morphology and chip profile. Corresponding numerical simulations with the analysis of built stress further validate experimental results and reveal the mechanisms governing the material anisotropy influence. The above findings provide insight into the fabrication of ultra-smooth surfaces of polycrystalline metals by ultra-precision diamond turning.

[1]  J. Rice,et al.  Rate sensitivity of plastic flow and implications for yield-surface vertices , 1983 .

[2]  N. Moronuki,et al.  Effect of Material Properties on Ultra Precise Cutting Processes , 1988 .

[3]  Yoshiyuki Uno,et al.  Cutting mechanism of fine ceramics with a single point diamond , 1989 .

[4]  D. L. Callahan,et al.  Origins of the Ductile Regime in Single-Point Diamond Turning of Semiconductors , 1995 .

[5]  E. Brinksmeier,et al.  GENERATION AND TEXTURE OF SURFACES IN ULTRAPRECISION CUTTING OF COPPER , 1997 .

[6]  Suet To,et al.  Ultraprecision diamond turning of aluminium single crystals , 1997 .

[7]  Fengzhou Fang,et al.  Diamond Cutting of Silicon with Nanometric Finish , 1998 .

[8]  B. Ngoi,et al.  Effect of tool and workpiece anisotropy on microcutting processes , 2001 .

[9]  C. Cheung,et al.  Effect of material anisotropy on shear angle prediction in metal cutting—a mesoplasticity approach , 2003 .

[10]  Jun'ichi Tamaki,et al.  Some observations on the wear of diamond tools in ultra-precision cutting of single-crystal silicon , 2003 .

[11]  Stefano Rossi,et al.  Improvement of surface finishing and corrosion resistance of prototypes produced by direct metal laser sintering , 2004 .

[12]  J. Michler,et al.  Investigation of wear mechanisms through in situ observation during microscratching inside the scanning electron microscope , 2005 .

[13]  Chi Fai Cheung,et al.  A study of materials swelling and recovery in single-point diamond turning of ductile materials , 2006 .

[14]  E. Brinksmeier,et al.  Ultra-Precision Diamond Cutting of Steel Molds , 2006 .

[15]  Wei Zhou,et al.  A study on mechanism of nano-cutting single crystal silicon , 2007 .

[16]  Jiwang Yan,et al.  Mechanism for material removal in diamond turning of reaction-bonded silicon carbide , 2009 .

[17]  R. Quey,et al.  Large-scale 3D random polycrystals for the finite element method: Generation, meshing and remeshing , 2011 .

[18]  Fengzhou Fang,et al.  Manufacturing and measurement of freeform optics , 2013 .

[19]  Eiji Shamoto,et al.  Fundamental investigation of ultra-precision ductile machining of tungsten carbide by applying elliptical vibration cutting with single crystal diamond , 2014 .

[20]  Fengzhou Fang,et al.  Nanometric cutting in a scanning electron microscope , 2015 .

[21]  Jianguo Zhang,et al.  Ultra-precision nano-structure fabrication by amplitude control sculpturing method in elliptical vibration cutting , 2015 .

[22]  Gang Wang,et al.  Experimental Study on the Surface Integrity and Chip Formation in the Micro Cutting Process , 2015 .

[23]  V. Silberschmidt,et al.  Micro-cutting of single-crystal metal: Finite-element analysis of deformation and material removal , 2016 .

[24]  Wenhao Du,et al.  Effect of cutting edge radius on surface roughness in diamond tool turning of transparent MgAl 2 O 4 spinel ceramic , 2017 .

[25]  Junjie Zhang,et al.  Sculpturing of single crystal silicon microstructures by elliptical vibration cutting , 2017 .

[26]  T. Sun,et al.  Coupled effect of crystallographic orientation and indenter geometry on nanoindentation of single crystalline copper , 2018, International Journal of Mechanical Sciences.

[27]  T. Sun,et al.  Atomistic and Experimental Investigation of the Effect of Depth of Cut on Diamond Cutting of Cerium , 2018, Micromachines.

[28]  K. Sørby,et al.  The effect of surface roughness on corrosion resistance of machined and epoxy coated steel , 2019, Progress in Organic Coatings.

[29]  F. Fang,et al.  Crystal plasticity finite element modeling and simulation of diamond cutting of polycrystalline copper , 2019, Journal of Manufacturing Processes.

[30]  Rui Li,et al.  In situ experimental study on material removal behaviour of single-crystal silicon in nanocutting , 2019, International Journal of Mechanical Sciences.

[31]  Guo Li,et al.  The interaction between grain boundary and tool geometry in nanocutting of a bi-crystal copper , 2019, International Journal of Extreme Manufacturing.

[32]  Kornel Ehmann,et al.  Towards atomic and close-to-atomic scale manufacturing , 2019, International Journal of Extreme Manufacturing.

[33]  T. Sun,et al.  Brittle-to-ductile transition in elliptical vibration-assisted diamond cutting of reaction-bonded silicon carbide , 2019, Journal of Manufacturing Processes.

[34]  F. Fang,et al.  Crystal anisotropy-dependent shear angle variation in orthogonal cutting of single crystalline copper , 2020 .

[35]  Guo Li,et al.  Towards an understanding of grain boundary step in diamond cutting of polycrystalline copper , 2020 .