Research Papers

Tool/Chip Interfacial Friction Analysis in Atomistic Machining of Polycrystalline Coppers

[+] Author and Article Information
Jing Shi

Department of Industrial and
Manufacturing Engineering,
North Dakota State University,
Dept. 2485, PO Box 6050,
Fargo, ND 58108
e-mail: Jing.shi@ndsu.edu

Chunhui Ji

School of Mechanical Engineering,
Tianjin University,
Nankai District,
Tianjin 300072, China
e-mail: ji_chunhui_love@126.com

Yachao Wang

Department of Industrial and
Manufacturing Engineering,
North Dakota State University,
Dept. 2485, PO Box 6050,
Fargo, ND 58108
e-mail: yachao.wang@my.ndsu.edu

Steve Hsueh-Ming Wang

Department of Engineering Science
Project Management,
University of Alaska Anchorage,
Anchorage, AK 99508
e-mail: hswang@uaa.alaska.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received April 16, 2014; final manuscript received July 14, 2014; published online July 29, 2014. Assoc. Editor: Hongqiang Chen.

J. Micro Nano-Manuf 2(4), 041001 (Jul 29, 2014) (9 pages) Paper No: JMNM-14-1032; doi: 10.1115/1.4028025 History: Received April 16, 2014; Revised July 14, 2014

Three-dimensional (3D) molecular dynamics (MD) simulation is performed to study the tool/chip interface friction phenomenon in machining of polycrystalline copper at atomistic scale. Three polycrystalline copper structures with the equivalent grain sizes of 12.25, 7.72, and 6.26 nm are constructed for simulation. Also, a monocrystalline copper structure is simulated as the benchmark case. Besides the grain size, the effects of depth of cut, cutting speed, and tool rake angle are also considered. It is found that the friction force and normal force distributions along the tool/chip interface in both polycrystalline and monocrystalline machining exhibit similar patterns. The reduction in grain size overall increases the magnitude of normal force along the tool/chip interface, but the normal forces in all polycrystalline cases are smaller than that in the monocrystalline case. In atomistic machining of polycrystalline coppers, the increase of depth of cut consistently increases the normal force along the entire contact area, but this trend cannot be observed for the friction force. In addition, both higher cutting speed and more negative tool rake angle do not bring significant changes to the distributions of normal and friction forces on the interface, but both factors tend to increase the magnitudes of the two force components.

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Fig. 2

Tool atom grouping on rake face for obtaining normal and friction stress distributions

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Fig. 1

Schematic of MD simulation model of polycrystalline machining

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Fig. 3

Snapshots of atomistic machining for case C1 at tool travel distance = (a) 15 nm and (b) 25 nm

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Fig. 4

Snapshots of atomistic machining for case C3 at tool travel distance = (a) 15 nm and (b) 25 nm

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Fig. 5

Contact length of tool/chip interface, (a) with various grain sizes of copper crystal for cases C1–C4 and (b) using different depths of cut for cases C5, C3, and C6

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Fig. 6

Cutting force evolution for cases (a) C1, (b) C2, (c) C3, and (d) C4

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Fig. 7

Average cutting forces for cases C1–C4

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Fig. 8

Tool/chip friction analysis for copper crystals with various grain sizes, (a) normal force and (b) friction force

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Fig. 9

Friction coefficient distributions for copper crystals with various grain sizes

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Fig. 10

Tool/chip stress profiles with four levels of depth of cut: (a) normal force and (b) friction force

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Fig. 11

Friction coefficient profiles with four levels of depth of cut

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Fig. 12

Friction analysis along tool/chip interface with the progress of machining for a polycrystalline copper: (a) normal force and (b) friction force

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Fig. 13

Friction coefficient distributions with the progress of machining for a polycrystalline copper

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Fig. 14

Comparison of tool/chip force distributions for cases C5 and C7: (a) normal force and (b) friction force

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Fig. 15

Comparison of tool/chip force distributions for cases C3 and C8, (a) normal force and (b) friction force



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