Molecular Dynamics Simulation Study on the Influence of the Abrasive Flow Process on the Cutting of Iron-Carbon Alloys (α-Fe)
Abstract
:1. Introduction
2. Materials and Methods
2.1. Model Building
2.2. Interatomic Potentials
2.3. Simulation Environment
3. Results and Discussion
3.1. Analysis of Liquid Phase Flow State and Effect
3.1.1. Analysis of Fluid Medium Flow State
3.1.2. Effect of Fluid Medium on Workpiece Temperature
3.1.3. Effect of Fluid Medium on Friction Coefficient
3.2. Evolution of Workpiece Surface Morphology
3.3. Analysis of Dislocation Evolution
4. Conclusions
- In comparison to machining without a fluid medium, machining using a fluid medium () lowers the machining temperature and the coefficient of friction.
- Temperature and coefficient of friction increase with increasing cutting angle during abrasive flow machining.
- The cutting angle has a greater influence on the formation of the workpiece’s surface profile and the manner in which the workpiece atoms are displaced, whereas the fluid medium has a lesser influence. When the cutting angle is 0°, 5° and 10°, respectively, the workpiece’s surface profile flows at 45° to both sides. The height of the atomic accumulation on the workpiece’s surface gradually decreases, but at the same time the area where displacement changes occur becomes larger. As the cutting angle increases, so does the depth of cut, resulting in more material damage.
- The area of displacement gradually expands towards the interior of the workpiece as the cutting angle increases. The number of atoms displaced to the workpiece’s surface decreases and remains within the workpiece. The atoms that accumulate inside the workpiece squeeze the uncut area, causing a bulge in the workpiece’s surface, which degrades the workpiece’s quality, but is beneficial for the removal of large burrs.
- During the cutting process, a large number of dislocations were discovered at b = 1/2 <1 1 1> and b = <1 0 0>. The b = 1/2 <1 1 1> dislocations dominate, with b = <1 0 0> connecting the dislocations in different areas. The dislocation reaction network is formed by the presence of a large number of single and double-branched structures within the workpiece. During large-angle cutting, the fluid medium can reduce the number of dislocations and the total dislocation length, which in turn reduces the generation of sub-surface defect structures, resulting in better machining quality.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Parameters | Values |
---|---|
Workpiece | Iron–carbon alloy |
Lattice structure | BCC |
Workpiece orientation | [100], [010], [001] |
Workpiece size | 114.52 Å × 171.78 Å × 85.89 Å |
Abrasive particle | SiC |
Radius of abrasive particle | 25 Å |
Atomic number of workpiece | 147,773 |
Atomic number of abrasive particle | 6287 |
Molecular number of fluid medium | 62,064 |
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Li, J.; Zhao, Z.; Li, J.; Xiao, F.; Qiu, R.; Xie, H.; Meng, W. Molecular Dynamics Simulation Study on the Influence of the Abrasive Flow Process on the Cutting of Iron-Carbon Alloys (α-Fe). Micromachines 2023, 14, 703. https://doi.org/10.3390/mi14030703
Li J, Zhao Z, Li J, Xiao F, Qiu R, Xie H, Meng W. Molecular Dynamics Simulation Study on the Influence of the Abrasive Flow Process on the Cutting of Iron-Carbon Alloys (α-Fe). Micromachines. 2023; 14(3):703. https://doi.org/10.3390/mi14030703
Chicago/Turabian StyleLi, Junye, Zhenguo Zhao, Junwei Li, Fujun Xiao, Rongxian Qiu, Hongcai Xie, and Wenqing Meng. 2023. "Molecular Dynamics Simulation Study on the Influence of the Abrasive Flow Process on the Cutting of Iron-Carbon Alloys (α-Fe)" Micromachines 14, no. 3: 703. https://doi.org/10.3390/mi14030703