Molecular dynamics simulation of the effect of tool parameters on nano-cutting of polycrystalline γ-TiAl alloys

As one of the most promising lightweight high-temperature structural materials in the future, the surface quality of γ-TiAl alloys has a great influence on the performance of the workpieces, and the tool parameters are an important factor affecting the machining results. In this study, molecular dynamics simulations of the nano-cutting process of polycrystalline γ-TiAl alloys with different tool parameters were carried out. The results show that increasing the tool rake angle and decreasing the tool edge radius within a certain range helps to reduce the average cutting force, cutting force fluctuation, cutting temperature, and stabilize the cutting process, while the change of the tool clearance angle has less influence on the cutting process. In contrast, negative rake angle cutting is more likely to produce grain rotation and grain boundary steps in the processed substrate and increase the processed surface roughness than positive rake angle cutting; increasing the tool rake angle within a certain range will weaken the elastic recovery effect of the substrate. During cutting at a positive rake angle, whether a portion of the substrate is prone to slip toward the surface of the substrate, thereby reducing the surface quality, depends on the relative state of grain orientation and force applied in the substrate.