Development of metal cutting process accompanied by a localized compressive hydrostatic stress field formation: Examination by molecular dynamics simulation

Improving machined surface integrity is important for precision machining. The aim of this work is to develop a cutting tool, which enables to generate a localized compressive hydrostatic stress field in the vicinity of cutting point to suppress unnecessary plastic flow and to improve the surface integrity of workpiece. In this paper, as the first step a simple cutting tool attached with a laminar jig equipped with a small rectangular hole for cutting chip elimination was proposed, and a molecular dynamics simulation of nano-cutting of monocrystalline aluminum was performed in order to verify and reveal the effectiveness and issues, respectively, of proposed method for improving machined surface integrity. The obtained simulation results were also compared to those using a normal cutting tool in order to clarify the cutting mechanism. As a result, it was clarified that a high compressive hydrostatic stress field was successfully introduced in the vicinity of cutting point. Consequently, the burr formation and elimination of cutting chip were remarkably suppressed and smoothened, respectively by using proposed cutting tool.