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    Modeling and analysis of tool wear mechanisms in diamond turning of copper beryllium alloy
    (Elsevier, 2020-08) Sharma, Anuj
    The interaction of hard Be particles in CuBe alloy with cutting tool, during diamond turning of CuBe contributes significantly to the tool wear. However, the mechanism of this interaction and its effect on tool wear have not been explored adequately thus far. Therefore, to understand the role of Be particles, diamond turning (facing) experiments were performed on Cu as well as CuBe alloys. The flank wear was assessed by SEM and Raman spectroscopy, the machined surfaces on the other hand, were assessed by EDS. MD simulations were also carried out to support the experimental findings. The experimental and simulation results show that the amorphization of diamond is the dominant tool wear mechanism, which indicates the transformation of sp3 phase of diamond structure while machining of CuBe. EDS analysis reveals that there are 15–20 % C atoms present on the location of hard particles on the machined surface which signifies that the Be particles are mainly responsible for tool wear. Forces recorded by dynamometer during cutting show that thrust forces are approximately one order higher for CuBe as compared to that of Cu. Furthermore, MDS results reveal that the principal cause of phase transformation in the diamond tool is high atomic stress in conjunction with the occurrence of high interface temperature.
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    An investigation of tool and hard particle interaction in nanoscale cutting of copper beryllium
    (Elsevier, 2018-04) Sharma, Anuj
    The present study adopts molecular dynamics simulation to analyze tool and hard particle interaction in the nano-cutting of copper beryllium (CuBe). The presence of hard particles in workpiece materials affects the cutting process in terms of surface generation, material deformation, and tool wear mechanisms. Therefore, in this simulation study, three cases are considered based on the distinct size and location of hard particle in the base material. Results show that Be particle, when encountered by a diamond tool at the cutting plane, is suppressed and subsequently is projected from the generated surface with a dig left behind the particle. Furthermore, particle removal or suppression depends on its size and location with respect to the cutting plane. Shockley partial dislocations are noticed to be dominant in plastically deforming the workpiece material. Moreover, it is not only the workpiece surface which gets affected; hard particle also deteriorates the tool by causing wear to its cutting edge. The cutting process – in terms of surface generation, material deformation, and tool edge condition – is found to be dependent on the crystallographic planes of the base material.
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    A molecular dynamics simulation of wear mechanism of diamond tool in nanoscale cutting of copper beryllium
    (Springer, 2019-01) Sharma, Anuj
    In the present study, molecular dynamics simulation (MDS) is employed to study the wear mechanism of single crystal diamond tool during nanocutting of copper beryllium (CuBe). Two edge configurations, i.e., both sharp and worn out tools, are chosen to study the tool and workpiece interaction during the nanocutting of CuBe. Further, the study involves the experimental characterization techniques viz. scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and Raman spectroscopy to confirm the simulation results. The results of the molecular dynamics simulation (MDS) show that the presence of Be as a hard particle in workpiece material influences the cutting forces which subsequently causes degradation of the sharp edge of the diamond tool. Furthermore, the carbon (C) atoms removed from the tool react with Be particles and as a result, it causes the formation of beryllium carbide (BeC). Beryllium interaction with the blunt edge configuration of the tool causes amorphization at the tool edge. Raman spectroscopy of the used diamond tool on CuBe reveals the similar phenomena of amorphization of the diamond at the tool edge. Moreover, surface generation is dependent on the tool edge condition as blunt edge tool leads to smoother surface compared to the surface generated by sharp edge configuration.