Analysis of material removal mechanism in nanoscale machining of copper

Abstract

In the current study, molecular dynamics modeling and simulation are carried out to analyse mechanisms in tool-workpiece interaction in nanoscale cutting. Various combinations of a/r ratios for constant r (r = tool edge radius and a = uncut chip thickness) are considered and different crystal orientations of the workpiece specimen are employed in the nanoscale cutting model. From the simulation, material anisotropy behavior is observed during the nanoscale cutting of copper material. Analysis at the molecular scale reveals that the crystal orientations family {1 1 0}<1 0 0> is hard to machine and the family of crystal planes {1 1 1}<1 1 0> is easiest to cut. While comparing in different crystal planes and directions, it was noticed that the material deformation in nanoscale machining takes place only in slip directions, that is, <1 1 0> family of directions. It is also found that as the uncut chip thickness is decreased, the cutting mechanism changes from shear plane cutting to plowing to sliding in Cu.