Title: Modelling the effects of tool edge radius on micro machining based on smooth particle hydrodynamics simulation method

Authors: Xiaoguang Guo; Xiaoji Zhang; Ziyuan Liu; Dongxiao Zhang; Zhuji Jin; Dongming Guo

Addresses: Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian, Liaoning, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian, Liaoning, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian, Liaoning, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian, Liaoning, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian, Liaoning, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, No. 2 Linggong Road, Ganjingzi District, Dalian, Liaoning, China

Abstract: Smooth particle hydrodynamics (SPH) method is introduced to simulate the oxygen-free copper micro-cutting process. At the same cutting thickness r, several different a/r are employed to investigate the effects of tool edge radius on the micromachining mechanism. The simulation results indicate that the larger a/r was, the greater the transverse cutting force was, the smaller the vertical pressure was, which benefits for material removal and good quality surface generation. And it could also be found that the cutting heat was smaller with the smaller a/r, the flows along the rake face generated a large amount of friction heat and oxygen came into the contact slit easily, which caused chemical corrosion on diamond rake face seriously. When the a/r was bigger, chemical corrosion becomes difficult because the cutting tool contacted the material adequately and oxygen was difficult to enter the contact zone.

Keywords: micromachining; SPH method; numerical simulation; modelling; tool edge radius; smooth particle hydrodynamics; copper cutting; transverse cutting force; vertical pressure; material removal; surface quality; surface roughness; friction heat; oxygen; chemical corrosion.

DOI: 10.1504/IJMMM.2014.067310

International Journal of Machining and Machinability of Materials, 2014 Vol.16 No.3/4, pp.303 - 317

Received: 23 Dec 2013
Accepted: 23 Jun 2014

Published online: 14 Feb 2015 *

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