Influence of the Rake Angle on Nanocutting of Fe Single Crystals: A Molecular-Dynamics Study
- Using molecular dynamics simulation, we study the cutting of an Fe single crystal using
tools with various rake angles α. We focus on the (110)[001] cut system, since here, the crystal
plasticity is governed by a simple mechanism for not too strongly negative rake angles. In this
case, the evolution of the chip is driven by the generation of edge dislocations with the Burgers
vector b = 1
2
[111], such that a fixed shear angle of φ = 54.7◦
is established. It is independent of
the rake angle of the tool. The chip form is rectangular, and the chip thickness agrees with the
theoretical result calculated for this shear angle from the law of mass conservation. We find that the
force angle χ between the direction of the force and the cutting direction is independent of the rake
angle; however, it does not obey the predictions of macroscopic cutting theories, nor the correlations
observed in experiments of (polycrystalline) cutting of mild steel. Only for (strongly) negative rake
angles, the mechanism of plasticity changes, leading to a complex chip shape or even suppressing the
formation of a chip. In these cases, the force angle strongly increases while the friction angle tends
to zero.