Li Xueguang, Pang Zhaohuan, Li Junsheng
Changchun University of Science and Technology, Changchun, Jilin Province, China.
Sci Rep. 2025 Mar 14;15(1):8847. doi: 10.1038/s41598-025-92946-1.
2024 aluminum alloy is widely used because of its high strength, low density, strong corrosion resistance, good heat resistance, light material and other excellent properties. However, in the ultra-precision machining process, its crystal structure often changes due to tool extrusion, resulting in changes in its physical properties such as plasticity and adhesion, which seriously affects the machining quality and tool wear. At present, aluminum alloy cutting is mainly carried out by cemented carbide tools. In this paper, the simulation experiment of WC tool cutting 2024 aluminum alloy is carried out based on MD (molecular dynamics) simulation method. The CNA (common neighbor analysis), DXA (dislocation analysis) and Coordination (coordination analysis) methods are used to study the tool diffusion wear mechanism and the influence of crystal evolution on tool diffusion wear based on the change of cutting parameters from the microscopic point of view. The results show that diffusion wear is the main factor causing WC tool wear. The defect evolution of the workpiece during the cutting process will directly affect the cutting force and cutting temperature, thus affecting the diffusion wear of the tool. The cutting speed, cutting width, cutting depth and tool clearance angle have a regular effect on the defect evolution of workpiece atoms and the order degree of tool atoms in the cutting process. At the same time, this paper verifies the correctness of the simulation results through milling experiments. The research results based on molecular dynamics simulation are reliable, which can greatly reduce the test cost and improve the efficiency of scientific research. It provides a reference for further improving the surface quality of ultra-precision cutting of aluminum-based alloy materials and reducing tool wear.
2024铝合金因其具有高强度、低密度、强耐腐蚀性、良好的耐热性、轻质材料等优异性能而被广泛应用。然而，在超精密加工过程中，其晶体结构常因刀具挤压而发生变化，导致其塑性和附着力等物理性能发生改变，严重影响加工质量和刀具磨损。目前，铝合金切削主要采用硬质合金刀具。本文基于分子动力学（MD）模拟方法，对WC刀具切削2024铝合金进行了模拟实验。基于切削参数的变化，从微观角度采用共邻分析（CNA）、位错分析（DXA）和配位分析（Coordination）方法研究刀具扩散磨损机理以及晶体演化对刀具扩散磨损的影响。结果表明，扩散磨损是导致WC刀具磨损的主要因素。切削过程中工件的缺陷演化会直接影响切削力和切削温度，进而影响刀具的扩散磨损。切削速度、切削宽度、切削深度和刀具后角在切削过程中对工件原子的缺陷演化和刀具原子的有序度有规律的影响。同时，本文通过铣削实验验证了模拟结果的正确性。基于分子动力学模拟的研究结果可靠，可大大降低试验成本，提高科研效率。为进一步提高铝基合金材料超精密切削的表面质量和减少刀具磨损提供了参考。
