Publications
Crystal plasticity finite element modeling and simulation of diamond cutting of polycrystalline copper
Z. Wang, J. Zhang, Z. Xu, H. u. Hassan, G. Li, H. Zhang, A. Hartmaier, F. Fang, T. Sun.
Journal of Manufacturing Processes, Elsevier Ltd., 38, 187-195, (2019)
Abstract
Microstructural-related deformation behavior leads to anisotropic machining characteristics of polycrystalline
materials. In the present work, we develop a crystal plasticity finite element model of ultra-precision diamond
cutting of polycrystalline copper, aiming to evaluate the influence of grain boundaries on the correlation between
microscopic deformation behavior of the material and macroscopic machining results. The crystal plasticity
dealing with the anisotropy of polycrystalline copper is implemented in a user subroutine (UMAT), and an
efficient element deletion technique based on the Johnson-Cook damage model is adopted to describe material
removal and chip formation. The effectiveness of as-established crystal plasticity finite element model is verified
by experiments of nanoindentation, nanoscratching and in-situ diamond microcutting. Subsequent crystal
plasticity finite element simulation of diamond cutting across a high angle grain boundary demonstrates significant
anisotropic machining characteristics in terms of machined surface quality, chip profile and cutting
force, due to heterogeneous plastic deformation behavior in the grain level.
DOI: 10.1016/j.jmapro.2019.01.007
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