Molecular dynamics simulation of elastic-plastic deformation associated with tool-workpiece contact in force sensor-integrated fast tool servo
YD Cai and YL Chen and Y Shimizu and S Ito and W Gao, PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE, 232, 1893-1902 (2018).
The tool-workpiece interactions when a single-point diamond cutting tool with specific tool edge geometry is made to contact with a copper workpiece are evaluated by the molecular dynamics simulations under different temperatures, boundary conditions and model sizes for ultra- precision microcutting and in-process surface form measurement based on a force sensor-integrated fast tool servo. It is confirmed that the proposed multi-relaxation time method is effective to stabilize the workpiece molecular dynamics model over a wide temperature range up to the room temperature under which a practical microcutting and on-machine surface form metrology process are conducted. The boundary condition and model size of the molecular dynamics model are then optimized to make reliable and cost-effective simulations for evaluation of the elastic- plastic transition contact depth and the corresponding contact force when a diamond tool with a practical edge sharpness of up to 30 nm is employed for microcutting and on-machine surface form metrology.
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