Abstract
Machinable ceramics are typical brittle materials, and their surface formation mechanism during machining has not been well revealed. Currently, there are few theoretical models of surface roughness for turning brittle materials. Through experiments with turning machinable ceramics, the surface formation mechanism of brittle materials is investigated from macro and micro perspectives. The combined action of tool and workpiece interference, elastic recovery, and crushing craters creates the machined surface of brittle materials. The initial surface angle and length, the deflection surface angle and length, and the extension length of the upward-extending surface were calculated based on the biaxial stress analytical method, the fracture criterion of the stress intensity factor, and the energy conservation principle. By quantitatively describing the cross-sectional shape of crushing craters, a brittle surface roughness model is established with the combination of actual cutting layer parameters, tool angle, material properties, tool-workpiece interference relationship, and elastic recovery. The experimental validation results show that the brittleness model is more accurate and consistent in trend compared to the traditional geometric model and the theoretical model of crushing with simplified crushing crater shapes. The new model can be utilized as a basis for the theoretical prediction of surface roughness in the cutting of brittle materials.
Similar content being viewed by others
Data availability
All data generated or analyzed during this study are included in this published article.
Code availability
Not applicable.
References
Ma L, Sun Z, Zhang L, Deng H, Tan Y, Kong Z, Wei Z (2020) Study on mechanism and theoretical model of tool wear in fluorophlogopite glass-ceramics turning. J Mater Process Technol 275:116284. https://doi.org/10.1016/j.jmatprotec.2019.116284
Shweta ASK, Hussain A, Fatima Z, Sharma K, Khanka S, Prakash R, Singh D, Gautam C (2023) Structural, morphological and mechanical insights from la2o3 doped machinable silicate glass ceramics for biomedical applications. Ceram Int 49:8801–8819. https://doi.org/10.1016/j.ceramint.2022.11.031
Ma L, He P, Deng H, Liu T, Tan Y, Zhou Y (2019) Theoretical model of characteristic temperature and continuous fracture mechanism of brittle material in the process of turning fluorophlogopite ceramics. Ceram Int 45:12521–12527. https://doi.org/10.1016/j.ceramint.2019.03.189
Lu J, Wang X, Chen S, Liao X, Chen K (2023) Surface roughness prediction for turning based on the corrected subsection theoretical model. Int J Adv Manuf Technol 124:21–35. https://doi.org/10.1007/s00170-022-10471-1
Junaid Mir M, Wani MF (2018) Modelling and analysis of tool wear and surface roughness in hard turning of AISI D2 steel using response surface methodology. Int J Ind Eng Comput 9(2018):63–74. https://doi.org/10.5267/j.ijiec.2017.4.004
Ma L, Gong Y, Chen X (2014) Study on surface roughness model and surface forming mechanism of ceramics in quick point grinding. Int J Mach Tools Manuf 77:82–92. https://doi.org/10.1016/j.ijmachtools.2013.11.001
Ma L, Li H (2022) Research progresses on surface roughness model of brittle material machining. Chin mech eng 33:757–768. https://doi.org/10.3969/j.issn.1004-132X.2022.07.001
Kuntoğlu M, Aslan A, Pimenov DY, Giasin K, Mikolajczyk T, Sharma S (2020) Modeling of cutting parameters and tool geometry for multi-criteria optimization of surface roughness and vibration via response surface methodology in turning of aisi 5140 steel. Materials (Basel) 13:4242. https://doi.org/10.3390/ma13194242
Khan A, Maity K (2018) A comprehensive GRNN model for the prediction of cutting force, surface roughness and tool wear during turning of CP-Ti grade 2. SILICON 10:2181–2191. https://doi.org/10.1007/s12633-017-9749-0
Su Y, Li C, Zhao G, Li C, Zhao G (2021) Prediction models for specific energy consumption of machine tools and surface roughness based on cutting parameters and tool wear. P I Mech Eng B-J Eng 235:1225–1234. https://doi.org/10.1177/0954405420971064
He CL, Zong WJ, Zhang JJ (2018) Influencing factors and theoretical modeling methods of surface roughness in turning process: state-of-the-art. Int J Mach Tool Manu 129:15–26. https://doi.org/10.1016/j.ijmachtools.2018.02.001
Pugazhenthi A, Kanagaraj G, Dinaharan I, Selvam JDR (2018) Turning characteristics of in situ formed tib2 ceramic particulate reinforced aa7075 aluminum matrix composites using polycrystalline diamond cutting tool. Measurement (Lond) 121:39–46. https://doi.org/10.1016/j.measurement.2018.02.039
Rafighi M, Özdemir M, Şahinoğlu A, Kumar R, Das SR (2022) Experimental assessment and topsis optimization of cutting force, surface roughness, and sound intensity in hard turning of aisi 52100 steel. Surf Rev Lett 29(11):2250150. https://doi.org/10.1142/S0218625X22501505
Zhang T, Liu Z, Shi Z, Xu C (2013) Size effect on surface roughness in micro turning. Int J Precis Eng Man 14:345–349. https://doi.org/10.1007/s12541-013-0048-4
Chang Z, Chen ZC, Wan N, Sun H (2018) A new mathematical method of modeling parts in virtual cnc lathing and its application on accurate tool path generation. Int J Adv Manuf Technol 95:243–256. https://doi.org/10.1007/s00170-017-1202-4
Felho C, Varga G (2022) Theoretical roughness modeling of hard turned surfaces considering tool wear. Machines 10:188. https://doi.org/10.3390/machines10030188
Tauhiduzzaman M, Veldhuis SC (2014) Effect of material microstructure and tool geometry on surface generation in single point diamond turning. Precis Eng 38:481–491. https://doi.org/10.1016/j.precisioneng.2014.01.002
Xu F, Fang F, Zhang X (2018) Effects of recovery and side flow on surface generation in nano-cutting of single crystal silicon. Comput Mater Sci 143:133–142. https://doi.org/10.1016/j.commatsci.2017.11.002
Mishra V, Khatri N, Nand K, Singh K, Sarepaka RGV (2015) Experimental investigation on uncontrollable parameters for surface finish during diamond turning. Mater Manuf Process 30:232–240. https://doi.org/10.1080/10426914.2014.952021
Vyroubal J (2012) Compensation of machine tool thermal deformation in spindle axis direction based on decomposition method. Precis Eng 36:121–127. https://doi.org/10.1016/j.precisioneng.2011.07.013
Sreejith PS (2008) Machining of 6061 aluminium alloy with mql, dry and flooded lubricant conditions. Mater Lett 62:276–278. https://doi.org/10.1016/j.matlet.2007.05.019
Zhang SJ, To S, Zhang GQ, Zhu ZW (2015) A review of machine-tool vibration and its influence upon surface generation in ultra-precision machining. Int J Mach Tool Manu 91:34–42. https://doi.org/10.1016/j.ijmachtools.2015.01.005
Gao Y, Sun R, Chen Y, Leopold J (2016) Analysis of chip morphology and surface topography in modulation assisted machining. Int J Mech Sci 111–112:88–100. https://doi.org/10.1016/j.ijmecsci.2016.03.025
Fu S, Yang H, Sun S, Zhang M, Liu Y, Zhang Y, Jiang Z, Pan L (2022) Investigation on the surface roughness modeling and analysis for ultra-precision diamond turning processes constrained by the complex multisource factors. P I Mech Eng B-J Eng 236:1295–1304. https://doi.org/10.1177/09544054221075878
Xing Y, Liu Y, Yang C, Xue C (2020) Roughness model of an optical surface in ultrasonic assisted diamond turning. Appl Opt 59:9722–9734. https://doi.org/10.1364/AO.402613
Tomov M, Kuzinovski M, Cichosz P (2016) Modeling and prediction of surface roughness profile in longitudinal turning. J Manuf Process 24:231–255. https://doi.org/10.1016/j.jmapro.2016.09.010
Tomov M, Gecevska V, Vasileska E (2022) Modelling of multiple surface roughness parameters during hard turning: a comparative study between the kinematical-geometrical copying approach and the design of experiments method (doe). Adv Prod Eng Manag 17:75–88. https://doi.org/10.14743/apem2022.1.422
Zong WJ, Huang YH, Zhang YL, Sun T (2014) Conservation law of surface roughness in single point diamond turning. Int J Mach Tool Manu 84:58–63. https://doi.org/10.1016/j.ijmachtools.2014.04.006
Zhang S, Zong W (2020) A novel surface roughness model for potassium dihydrogen phosphate (kdp) crystal in oblique diamond turning. Int J Mech Sci 173:105462. https://doi.org/10.1016/j.ijmecsci.2020.105462
He CL, Zong WJ, Sun T (2016) Origins for the size effect of surface roughness in diamond turning. Int J Mach Tool Manu 106:22–42. https://doi.org/10.1016/j.ijmachtools.2016.04.004
He C, Yan J, Wang S, Zhang S, Chen G, Ren C (2023) A theoretical and deep learning hybrid model for predicting surface roughness of diamond-turned polycrystalline materials. Int J Extreme Manuf 5:35102. https://doi.org/10.1088/2631-7990/acdb0a
Ma L, Cai C, Tan Y, Gong Y, Zhu L (2019) Theoretical model of transverse and longitudinal surface roughness and study on brittle-ductile transition mechanism for turning fluorophlogopite ceramic. Int J Mech Sci 150:715–726. https://doi.org/10.1016/j.ijmecsci.2018.10.059
Ma L, Cai C, Bi C, Zhang L (2019) Brittle fracture mechanism and surface roughness model in turning fluorophlogopite ceramics. J Northeastern Univ (Nat Sci) 40:239–243+250. https://doi.org/10.12068/j.issn.1005-3026.2019.02.017
Jia J, Ma L, Du W, Sun Y, Dai C, Tan Y, Zhou Y (2023) Study on the unstable crack propagation mechanism in turning machinable ceramics based on the energy conversion principle and the fracture mechanics theory. Int J Adv Manuf Technol 127:4591–4606. https://doi.org/10.1007/s00170-023-11817-z
Arcona C, Dow TA (1998) An empirical tool force model for precision machining. J Manuf Sci Eng 120:700–707. https://doi.org/10.1115/1.2830209
Funding
This work was supported by the National Natural Science Foundation of China (grant number 51975113), the National Natural Science Foundation of China (grant number 52305453), and the National Natural Science Foundation of China (grant number 52065052).
Author information
Authors and Affiliations
Contributions
Jing Jia: Conceptualization, Methodology, Software, Experiment, Writing—Original Draft, Writing—Review & Editing. Lianjie Ma: Supervision, Writing—Review & Editing, Funding Acquisition, Resources. Yang Sun: Software, Investigation. Dezhen Li: Validation. Wenzhi Liu: Investigation. Zhibin Han: Experiment. Ming Li: Supervision.
Corresponding author
Ethics declarations
Ethics approval
Not applicable.
Consent to participate
Consent.
Consent for publication
Consent.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Jia, J., Ma, L., Sun, Y. et al. Study on the surface formation mechanism and theoretical model of brittle surface roughness in turning machinable ceramics. Int J Adv Manuf Technol 130, 3877–3889 (2024). https://doi.org/10.1007/s00170-023-12895-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-12895-9