Research Papers

Molecular Dynamics Simulation Study of Tool Wear in Vibration Assisted Nano-Impact-Machining by Loose Abrasives

[+] Author and Article Information
Sagil James

Department of Mechanical and
Materials Engineering,
University of Cincinnati,
Cincinnati, OH 45221
e-mail: jamess5@mail.uc.edu

Murali M. Sundaram

Department of Mechanical
and Materials Engineering,
University of Cincinnati,
Cincinnati, OH 45221
e-mail: murali.sundaram@uc.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO AND NANO-MANUFACTURING. Manuscript received September 25, 2013; final manuscript received October 3, 2014; published online October 30, 2014. Assoc. Editor: Bin Wei.

J. Micro Nano-Manuf 3(1), 011001 (Oct 30, 2014) (7 pages) Paper No: JMNM-13-1071; doi: 10.1115/1.4028782 History: Received September 25, 2013; Revised October 03, 2014

Vibration assisted nano-impact-machining by loose abrasives (VANILA) is a novel target specific nano-abrasive machining process wherein, nano-abrasives, injected in slurry between the workpiece and the vibrating atomic force microscope probe, impact the workpiece causing nanoscale material removal. In this study, a molecular dynamics (MD) based simulation approach is used to investigate the tool wear mechanism. The simulation results reveal that the tool wear is influenced by the impact velocity of the abrasive grains and the effective tool tip radius. It is seen that based on the process conditions, the wear process could happen through distinctive mechanisms such as atom-by-atom loss, plastic deformation, and brittle fracture. Experimental results show evidences of tool wear by aforementioned mechanisms in VANILA process.

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Fig. 1

Schematic of the VANILA process: (a) Tool striking the abrasive particle, (b) abrasive particle impacting workpiece surface, and (c) material removal from the workpiece.

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Fig. 2

VANILA process machining results: (a) Pattern design, (b) AFM image of nanocavities machined on silicon substrate [2], (c) pattern design, and (d) AFM image of nanocavities machined on borosilicate glass substrate.

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Fig. 3

Schematic of MD simulation model used to study tool tip wear during VANILA process

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Fig. 4

MD simulation of tool wear in VANILA process: (a) before impact and (b) after impact

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Fig. 5

Possible mechanisms of tool wear during VANILA process: (a) Atom-by-atom attrition, (b) ductile mode, and (c) radial cracking

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Fig. 6

Tool wear mechanism map

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Fig. 7

Number of atoms removed versus impact velocity

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Fig. 8

Number of atoms removed versus abrasive grain size

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Fig. 9

Number of atoms removed versus effective tip radius

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Fig. 10

Tool tip showing wear zones

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Fig. 11

SEM images showing tool wear of silicon tips used in VANILA process: (a) Side view before machining, (b) bottom view before machining, (c) side view atom-by-atom loss, (d) bottom view atom-by-atom loss, (e) side view plastic deformation, (f) bottom view plastic deformation, (g) side view brittle fracture, and (h) bottom view brittle fracture.




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