Guangzhou Wang , Linjie Zhao , Qi Liu , Yazhou Sun , Mingjun Chen
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The experimental observation of cutting forces and specific cutting forces verified the evolution of three cutting modes, including shearing, shearing-ploughing and ploughing in the micro-cutting of GDP with the decrease of <em>RTS</em>. Next, from the change of the node displacement vector observed from the simulated results, it can be seen that the real-time material flow behavior during micro-cutting of GDP varies obviously with the evolution of cutting modes. Besides, the fracture toughness <em>G</em><sub><em>c</em></sub>, and the energy dissipation of different cutting modes were analyzed. The proportion of the energy spent on material fracture (<em>G</em><sub><em>c</em></sub>=9.95 N/mm) is the largest one in shearing and shearing-ploughing modes, while in ploughing mode, the material plastic deformation consumed the most energy. The above results reveal the specific material properties and removal behaviors of GDP and contribute to optimizing the machining strategies for the practical micromachining of microstructures on material surfaces.</p></div>","PeriodicalId":56011,"journal":{"name":"CIRP Journal of Manufacturing Science and Technology","volume":null,"pages":null},"PeriodicalIF":4.6000,"publicationDate":"2024-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Investigating micro-cutting mechanism of glow discharge polymer based on material properties and removal behaviors analysis\",\"authors\":\"Guangzhou Wang , Linjie Zhao , Qi Liu , Yazhou Sun , Mingjun Chen\",\"doi\":\"10.1016/j.cirpj.2024.03.006\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"<div><p>Glow discharge polymer (GDP) is the unique artificial material for the target balls in Inertial Confinement Fusion tests, while its practical micromachining such as the fabrication of microstructure on material surfaces keeps challenging due to its unclear micro-cutting mechanism. Hence, this paper seeks to investigate the micro-cutting mechanism of GDP from the perspective of the material flow and cutting energy. To achieve it, the energy conservation equation of three cutting modes triggered by different ratios of uncut chip thickness to the tool cutting edge radius (<em>RTS</em>) was established based on cutting deformation behaviors. Meanwhile, the diamond cutting tests and the FEM simulation at different <em>RTS</em> were developed. The experimental observation of cutting forces and specific cutting forces verified the evolution of three cutting modes, including shearing, shearing-ploughing and ploughing in the micro-cutting of GDP with the decrease of <em>RTS</em>. Next, from the change of the node displacement vector observed from the simulated results, it can be seen that the real-time material flow behavior during micro-cutting of GDP varies obviously with the evolution of cutting modes. Besides, the fracture toughness <em>G</em><sub><em>c</em></sub>, and the energy dissipation of different cutting modes were analyzed. The proportion of the energy spent on material fracture (<em>G</em><sub><em>c</em></sub>=9.95 N/mm) is the largest one in shearing and shearing-ploughing modes, while in ploughing mode, the material plastic deformation consumed the most energy. 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引用次数: 0
摘要
辉光放电聚合物(GDP)是惯性约束聚变试验中靶球的独特人造材料,但由于其微切割机理不清,其实际微加工(如在材料表面制造微结构)一直面临挑战。因此,本文试图从材料流动和切割能量的角度研究 GDP 的微切割机理。为此,本文基于切削变形行为,建立了未切削切屑厚度与刀具切削刃半径(RTS)的不同比值所引发的三种切削模式的能量守恒方程。同时,建立了不同 RTS 下的金刚石切削试验和有限元模拟。通过对切削力和比切削力的实验观察,验证了随着 RTS 的减小,GDP 微切削过程中出现了剪切、剪切-犁削和犁削三种切削模式的演变。其次,从模拟结果中观察到的节点位移矢量变化可以看出,GDP 微切割过程中的实时材料流动行为随着切割模式的演变而发生明显变化。此外,还分析了断裂韧性 Gc 和不同切割模式的能量耗散。在剪切模式和剪切-犁切模式中,材料断裂耗能(Gc=9.95 N/mm)所占比例最大,而在犁切模式中,材料塑性变形耗能最大。上述结果揭示了 GDP 的特定材料特性和去除行为,有助于优化加工策略,以实现材料表面微结构的实际微加工。
Investigating micro-cutting mechanism of glow discharge polymer based on material properties and removal behaviors analysis
Glow discharge polymer (GDP) is the unique artificial material for the target balls in Inertial Confinement Fusion tests, while its practical micromachining such as the fabrication of microstructure on material surfaces keeps challenging due to its unclear micro-cutting mechanism. Hence, this paper seeks to investigate the micro-cutting mechanism of GDP from the perspective of the material flow and cutting energy. To achieve it, the energy conservation equation of three cutting modes triggered by different ratios of uncut chip thickness to the tool cutting edge radius (RTS) was established based on cutting deformation behaviors. Meanwhile, the diamond cutting tests and the FEM simulation at different RTS were developed. The experimental observation of cutting forces and specific cutting forces verified the evolution of three cutting modes, including shearing, shearing-ploughing and ploughing in the micro-cutting of GDP with the decrease of RTS. Next, from the change of the node displacement vector observed from the simulated results, it can be seen that the real-time material flow behavior during micro-cutting of GDP varies obviously with the evolution of cutting modes. Besides, the fracture toughness Gc, and the energy dissipation of different cutting modes were analyzed. The proportion of the energy spent on material fracture (Gc=9.95 N/mm) is the largest one in shearing and shearing-ploughing modes, while in ploughing mode, the material plastic deformation consumed the most energy. The above results reveal the specific material properties and removal behaviors of GDP and contribute to optimizing the machining strategies for the practical micromachining of microstructures on material surfaces.
期刊介绍:
The CIRP Journal of Manufacturing Science and Technology (CIRP-JMST) publishes fundamental papers on manufacturing processes, production equipment and automation, product design, manufacturing systems and production organisations up to the level of the production networks, including all the related technical, human and economic factors. Preference is given to contributions describing research results whose feasibility has been demonstrated either in a laboratory or in the industrial praxis. Case studies and review papers on specific issues in manufacturing science and technology are equally encouraged.