Cutting Experiments in a Computer using Atomic Models of a Copper Crystal and a Diamond Tool

In order to analyze the mechanism of nanometer cutting, a method of atomic-scale cutting in an experiment using a computer has been developed based on the nonlinear finite-element formulation which regards atoms and atomic interaction as nodes and elements, respectively. This method can handle discontinuous phenomena due to instantaneous propagation of dislocation in a workpiece during cutting. Experiments carried out using two kinds of assumed potential energy between tool and workpiece atoms have revealed that the process of chip formation as well as the stress distribution on the tool face during cutting is strongly dependent on the type of interaction energy between the tool and workpiece, while the size effect for the specific cutting coefficient and the discontinuity of cutting force variation during cutting are common in both types of potential energy. The experiments have also shown that the intermittent drop of potential energy accumulated in the workpiece during cutting results in heat generation associated with plastic deformation of the workpiece, while the heat generation repeatedly causes impulsive temperature rise on the tool face during cutting.