On the mechanism of dislocation-dominated chip formation in cutting-based single atomic layer removal of monocrystalline copper

Abstract

For mechanical cutting, when cutting depth is decreased to the atomic scale, minimum chip thickness could be down to a single atomic layer. The material removal is conducted in a new dislocation-dominated chip formation mechanism. It is different from the extrusion-dominated nano-cutting and concentrated shearing-dominated chip formation in micromachining. Serials of molecular dynamics simulations indicate that there are three deformation zones generated within the contact zone between the cutting tool and workpiece materials, including a dislocation slip zone, a chip formation zone and an elastic deformation zone. Under their cooperation, the final material removal could be achieved with a single atomic layer precision. The processed surfaces with a single atomic layer precision can be achieved through this new chip formation mechanism.

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Funding

This study was financially supported by the Science Foundation Ireland (SFI) (No. 15/RP/B3208) and ‘111’ project by the State Administration of Foreign Experts Affairs and the Ministry of Education of China (Grant No. B07014).

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Correspondence to Fengzhou Fang.

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Xie, W., Fang, F. On the mechanism of dislocation-dominated chip formation in cutting-based single atomic layer removal of monocrystalline copper. Int J Adv Manuf Technol 108, 1587–1599 (2020). https://doi.org/10.1007/s00170-020-05527-z

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Keywords

  • ACSM
  • Mechanical cutting
  • Chip formation mechanism
  • Dislocation
  • Single atomic layer removal