Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining

IF 4.2 2区 工程技术 Q2 ENGINEERING, MANUFACTURING
Chao-Jun Zhang, Song-Qing Li, Pei-Xuan Zhong, Fei-Fan Zhang, Wen-Jun Deng
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Abstract

In the traditional machining field, the addition of cutting fluid can appropriately reduce cutting forces, dissipate cutting heat, and facilitate the machining process. However, the use of cutting fluids has environmental implications. Recently, a phenomenon known as organic monolayer embrittlement (OME) has been proposed, which could address this issue. OME can reduce cutting forces, enhance surface quality, and improve machining performance without the need for cutting fluids, particularly noticeable in ductile metals like pure copper. This study conducted micro-cutting experiments on pure copper to investigate the microstructural features, cutting performance, chip flow patterns, and the effectiveness of OME. The results indicate that OME alters chip flow patterns from sinuous flow to segmented quasi-periodic micro-fracture flow, resulting in a 42% and 63% reduction in cutting forces for copper materials with different initial hardness. This phenomenon significantly improves surface quality, diminishes surface defects caused by adhesion, and effectively reduces work hardening layers. The study also demonstrates that OME is a physical phenomenon closely related to the adsorption properties of organic catalytic agents and van der Waals interactions. Materials with higher initial hardness exhibit less pronounced OME due to a sufficiently high grain boundary density, impeding dislocation movement during shear deformation and causing a local stress increase at the free surface of the chip. This leads to a change in chip flow patterns, improving machining performance, analogous to the adsorption effect of organic catalytic agents.

Abstract Image

韧性金属精密加工中有机单层脆化的切削性能和效果评估
在传统的机械加工领域,添加切削液可以适当降低切削力,散发切削热,促进加工过程。然而,切削液的使用会对环境造成影响。最近,一种被称为有机单层脆化(OME)的现象被提出,它可以解决这一问题。OME 可以降低切削力,提高表面质量,改善加工性能,而无需使用切削液,这在纯铜等韧性金属中尤为明显。本研究对纯铜进行了微切削实验,以研究其微观结构特征、切削性能、切屑流动模式以及 OME 的有效性。结果表明,OME 改变了切屑流动模式,从蜿蜒流动变为分段准周期微裂纹流动,从而使不同初始硬度的铜材料的切削力分别降低了 42% 和 63%。这种现象明显改善了表面质量,减少了因粘附造成的表面缺陷,并有效减少了加工硬化层。研究还表明,OME 是一种物理现象,与有机催化剂的吸附特性和范德华相互作用密切相关。初始硬度较高的材料由于晶界密度足够高,在剪切变形过程中会阻碍位错运动,并导致切屑自由表面的局部应力增加,从而表现出较不明显的 OME。这导致了切屑流动模式的改变,提高了加工性能,类似于有机催化剂的吸附效应。
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来源期刊
Advances in Manufacturing
Advances in Manufacturing Materials Science-Polymers and Plastics
CiteScore
9.10
自引率
3.80%
发文量
274
期刊介绍: As an innovative, fundamental and scientific journal, Advances in Manufacturing aims to describe the latest regional and global research results and forefront developments in advanced manufacturing field. As such, it serves as an international platform for academic exchange between experts, scholars and researchers in this field. All articles in Advances in Manufacturing are peer reviewed. Respected scholars from the fields of advanced manufacturing fields will be invited to write some comments. We also encourage and give priority to research papers that have made major breakthroughs or innovations in the fundamental theory. The targeted fields include: manufacturing automation, mechatronics and robotics, precision manufacturing and control, micro-nano-manufacturing, green manufacturing, design in manufacturing, metallic and nonmetallic materials in manufacturing, metallurgical process, etc. The forms of articles include (but not limited to): academic articles, research reports, and general reviews.
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