Abstract
This paper reviews the application of the molecular dynamics simulation approach to the high-resolution visualization of the plastic material flow at the tool/workpiece interface during orthogonal cutting. MD simulation techniques have been applied to nano-scale processes, but due to restrictions in the model size and computational time, they have not been utilized to investigate processes occurring at the micro-scale. Techniques employed to extend the MD simulation techniques to the micro-scale are discussed. Preferred ranges for model parameters that provide for sufficient resolution in order to adequately describe the characteristic features of the plastic material flow, yet achieve significant reduction in the model computational times, are identified. An investigation of the plastic material flow at the tool/workpiece interface as the uncut chip thickness increases from 10% to 90% of the edge radius of the tool was undertaken. A key observation is that there is a marked variation in the geometry of the observed characteristic features, most notable being the rotation and growth of the stable built-up edge as the uncut chip thickness increases. Furthermore, the transition between the plowing and cutting regimes is observed.
Similar content being viewed by others
References
Chuzhoy, L., Devor, R. E., Kapoor, S. G., Beaudoin, A. J., and Bammann, D. J., “Machining Simulation of Ductile Iron and Its Constituents, Part 1: Estimation of Material Model Parameters and Their Validation,” Journal of Manufacturing Science and Engineering, Vol. 125, No. 2, pp. 181–191, 2003.
Vogler, M. P., Devor, R. E., and Kapoor, S. G., “Microstructure-Level Force Prediction Model for Micro-Milling of Multi-Phase Materials,” Journal of Manufacturing Science and Engineering, Vol. 125, No. 2, pp. 202–209, 2003.
Basuray, P. K., Misra, B. K., and Lal, G. K., “Transition from Ploughing to Cutting During Machining with Blunt Tools,” Wear, Vol. 43, No. 3, pp. 341–349, 1977.
Yuan, Z. J., Zhou, M., and Dong, S., “Effect of Diamond Tool Sharpness on Minimum Cutting Thickness and Cutting Surface Integrity in Ultraprecision Machining,” Journal of Materials Processing Technology, Vol. 62, No. 4, pp. 327–330, 1996.
Weule, H., Huntrup, V., and Tritschle, H., “Micro-Cutting of Steel to Meet New Requirements in Miniaturization,” Annals of the CIRP, Vol. 50, No. 1, pp. 61–64, 2001.
Kim, C.-J., Bono, M., and Ni, J., “Experimental Analysis of Chip Formation in Micro-Milling,” Transactions of NAMRI/SME, Vol. 30, pp. 247–254, 2002.
Kim, C.-J., “Mechanisms of Chip Formation and Cutting Dynamics in the Micro-Scale Milling Process,” Ph.D. Thesis, Mechanical Engineering, University of Michigan, 2004.
Palmer, W. B. and Yeo, C. K., “Metal Flow near the Tool Point During Orthogonal Cutting with a Blunt Tool,” Proceedings of the 4th International Machine Tool Design and Research Conference, pp. 61–71, 1963.
Abdelmoneim, M. E. and Scrutton, R. F., “Tool Edge Roundness and Stable Build-up Formation in Finish Machining,” Journal of Engineering for Industry, Vol. 96, No. 4, pp. 1258–1267, 1974.
Kountanya, R. K., “Process Mechanics of Metal Cutting with Edge Radiused and Worn Tools,” Ph.D. Thesis, Mechanical Engineering, University of Michigan, 2002.
Inamura, T., Takezawa, N., and Taniguchi, N., “Atomic-Scale Cutting in a Computer Using Crystal Models of Copper and Diamond,” Annals of the CIRP, Vol. 41, No. 1, pp. 121–124, 1992.
Shimada, S., Ikawa, N., Tanaka, H., Ohmori, G., Uchikoshi, J., and Yoshinaga, H., “Feasibility Study on Ultimate Accuracy in Microcutting Using Molecular Dynamics Simulation,” Annals of the CIRP, Vol. 42, No. 1, pp. 91–94, 1993.
Komanduri, R., Chandrasekaran, N., and Raff, L. M., “Effect of Tool Geometry in Nanometric Cutting: A Molecular Dynamics Simulation Approach,” Wear, Vol. 219, No. 1, pp. 84–97, 1998.
Maekawa, K. and Itoh, A., “Friction and Tool Wear in Nano-Scale Machining — a Molecular Dynamics Approach,” Wear, Vol. 188, No. 1–2, pp. 115–122, 1995.
Kim, K. W. and Sin, H.-C., “Development of a Thermo-Viscoplastic Cutting Model Using Finite Element Method,” International Journal of Machine Tools and Manufacture, Vol. 36, No. 3, pp. 379–397, 1996.
Taupin, E., Breitling, J., Wu, W.-T., and Altan, T., “Material Fracture and Burr Formation in Blanking Results of Fem Simulations and Comparison with Experiments,” Journal of Materials Processing Technology, Vol. 59, No. 1–2, pp. 68–78, 1996.
Lin, Z.-C. and Lin, Y.-Y., “Fundamental Modeling for Oblique Cutting by Thermo-Elastic-Plastic Fem,” International Journal of Mechanical Sciences, Vol. 41, No. 8, pp. 941–965, 1999.
Swope, W. C., Andersen, H. C., Berens, P. H., and Wilson, K. R., “A Computer Simulation Method for the Calculation of Equilibrium Constants for the Formation of Physical Clusters of Molecules: Application to Small Water Clusters,” Journal of Chemical Physics, Vol. 76, No. 1, pp. 637–649, 1982.
Courtney, T. H., “Mechanical Behavior of Materials,” McGraw-Hill, pp. 86–88, 2000.
Ueda, K. and Iwata, K., “Chip Formation Mechanism in Single Crystal Cutting of Beta-Brass,” Annals of the CIRP, Vol. 29, No. 1, pp. 41–46, 1980.
Sato, M., Kato, Y., Tsutiya, K., and Aoki, S., “Effects of Crystal Orientation on the Cutting Mechanism of Aluminum Single Crystal,” Bulletin of the JSME, Vol. 24, No. 196, pp. 1864–1870, 1981.
Shirakashi, T., Yoshino, M., and Kurashima, H., “Simulation of Cutting Process of Single Crystal Aluminum,” International Journal of JSPE, Vol. 25, No. 3, pp. 181–186, 1991.
Yousefi, R. and Ichida, Y., “A Study on Ultra-High-Speed Cutting of Aluminum Alloy: Formation of Welded Metal on the Secondary Cutting Edge of the Tool and Its Effects on the Quality of Finished Surface,” Precision Engineering, Vol. 24, pp. 371–376, 2000.
Lucca, D. A., Rhorer, R. L., and Komanduri, R., “Energy Dissipation in the Ultraprecision Machining of Copper,” Annals of the CIRP, Vol. 40, No. 1, pp. 69–72, 1991.
Zhang, L. and Tanaka, H., “Towards a Deeper Understanding of Wear and Friction on the Atomic Scale-a Molecular Dynamics Analysis,” Wear, Vol. 211, No. 1, pp. 44–53, 1997.
Kim, C.-J., Mayor, R., and Ni, J., “A Static Model of Chip Formation in Microscale Milling,” Journal of Manufacturing Science and Engineering, Vol. 126, No. 4, pp. 710–718, 2004.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kim, CJ., Mayor, R. & Ni, J. Molecular dynamics simulations of plastic material deformation in machining with a round cutting edge. Int. J. Precis. Eng. Manuf. 13, 1303–1309 (2012). https://doi.org/10.1007/s12541-012-0173-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-012-0173-5