Crystal anisotropy-dependent shear angle variation in orthogonal cutting of single crystalline copper |
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| Affiliation: | 1. Centre of Micro/Nano Manufacturing Technology (MNMT-Dublin), University College Dublin, Dublin, Ireland;2. State Key Laboratory of Precision Measuring Technology and Instruments, Centre of Micro/Nano Manufacturing Technology (MNMT), Tianjin University, Tianjin, China;1. Wolfson School of Mechanical, Electrical and Manufacturing Engineering, Loughborough University, Loughborough LE11 3TU, UK;2. Department of Mechanical Engineering, Tokyo Denki University, 2-2 Kanda-Nishiki-cho, Chiyoda-ku, Tokyo 101-8457, Japan;1. Tianjin Key Laboratory of Equipment Design and Manufacturing Technology, Tianjin University, Tianjin, 30054, China;2. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, Hubei, 430074, China;3. Tianjin Key Laboratory of the Design and Intelligent Control of the Advanced Mechatronical System, School of Mechanical Engineering, Tianjin University of Technology, Tianjin, 300384, China;4. Institute of Chemical Materials, China Academy of Engineering Physics, Mianyang, Sichuan, 621900, China;1. State Key Lab of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China;2. Wolfson School of Mechanical, Electrical and Manufacturing Engineering, Loughborough University, Leicestershire, LE11 3TU, UK;3. Shanghai Aerospace Control Technology Institute, Shanghai, 201109, China |
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| Abstract: | Shear deformation that dominates elementary chip formation in metal cutting greatly relies on crystal anisotropy. In the present work we investigate the influence of crystallographic orientation on shear angle in ultra-precision orthogonal diamond cutting of single crystalline copper by joint crystal plasticity finite element simulations and in-situ experiments integrated in scanning electron microscope. In particular, the experimental cutting conditions including a straight cutting edge are the same with that used in the 2D finite element simulations. Both simulations and experiments demonstrate a well agreement in chip profile and shear angle, as well as their dependence on crystallography. A series of finite element simulations of orthogonal cutting along different cutting directions for a specific crystallographic orientation are further performed, and predicated values of shear angle are used to calibrate an extended analytical model of shear angle based on the Ernst–Merchant relationship. |
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| Keywords: | Diamond cutting Single crystalline copper Crystal anisotropy Shear angle Crystal plasticity finite element |
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