Cutting Experiments in a Computer Using Atomic Models of a Copper Crystal and a Diamond Tool

Abstract

A method of atomic scale cutting in a computer has been developed based on the nonlinear finite element formulation which regards atoms and atomic interaction as nodes and elements, respectively. This method can handle discontinuous phenomena due to instantaneous propagation of dislocation in a workpiece during cutting. Experiments carried out using two kinds of assumed interactive potential energy between tool and workpiece atoms have revealed that the process of chip formation as well as the stress distribution on the tool face during cutting is strongly dependent on the type of interaction energy between the tool and workpiece, while the size effect for the specific cutting coefficient and the discontinuity of cutting force variation during cutting are common in both types of potential energy. The experiments have also shown that the intermittent drop of the potential energy accumulated in the workpiece during cutting is the result of heat generation associated with plastic deformation of the workpiece, while the heat generation causes impulsive temperature rise on the tool face repeatedly during cutting.