Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining

doi:10.1007/s40436-024-00513-0

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (2): 395-412.doi: 10.1007/s40436-024-00513-0

Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining

Chao-Jun Zhang, Song-Qing Li, Pei-Xuan Zhong, Fei-Fan Zhang, Wen-Jun Deng

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510641, People's Republic of China

收稿日期:2023-12-17 修回日期:2024-02-15 发布日期:2025-05-16
通讯作者: Wen-Jun Deng,E-mail:dengwj@scut.edu.cn E-mail:dengwj@scut.edu.cn
作者简介:Chao-Jun Zhang is now studying for an M.S. degree from School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China. His current research interest is advanced manufacturing technology and machining technology of difficult-to-cut materials.
Song-Qing Li is now studying for a Ph.D. degree from School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China. His current research interest is metal cutting and machining mechanism.
Pei-Xuan Zhong is now studying for a Ph.D. degree from School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China. His current research interest is numerical simulation of machining process and tool design.
Fei-Fan Zhang is now studying for an M.S. degree from School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, China. His current research interest is gradient structure metal material.
Wen-Jun Deng is a professor of School of Mechanical and Automotive Engineering, South China University of Technology Guangzhou, China. He received his Ph.D. degree in Mechanical Engineering from South China University of Technology. His research interests include machining technology of difficult-to-cut materials, numer ical simulation of machining process, ultrafine grain materials/nanocrystalline materials.
基金资助:
This work was supported by the National Natural Science Foundation of China (Grant No. 52075187), the Natural Science Foundation of Guangdong Province (Grant No.2022A1515010995), and the Fundamental Research Funds for the Central University (Grant No. 2017ZD024).

Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining

Chao-Jun Zhang, Song-Qing Li, Pei-Xuan Zhong, Fei-Fan Zhang, Wen-Jun Deng

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510641, People's Republic of China

Received:2023-12-17 Revised:2024-02-15 Published:2025-05-16
Contact: Wen-Jun Deng,E-mail:dengwj@scut.edu.cn E-mail:dengwj@scut.edu.cn
Supported by:
This work was supported by the National Natural Science Foundation of China (Grant No. 52075187), the Natural Science Foundation of Guangdong Province (Grant No.2022A1515010995), and the Fundamental Research Funds for the Central University (Grant No. 2017ZD024).

摘要/Abstract

摘要： In the traditional machining field, the addition of cutting fluid can appropriately reduce cutting forces, dissipate cutting heat, and facilitate the machining process. However, the use of cutting fluids has environmental implications. Recently, a phenomenon known as organic monolayer embrittlement (OME) has been proposed, which could address this issue. OME can reduce cutting forces, enhance surface quality, and improve machining performance without the need for cutting fluids, particularly noticeable in ductile metals like pure copper. This study conducted micro-cutting experiments on pure copper to investigate the microstructural features, cutting performance, chip flow patterns, and the effectiveness of OME. The results indicate that OME alters chip flow patterns from sinuous flow to segmented quasi-periodic micro-fracture flow, resulting in a 42% and 63% reduction in cutting forces for copper materials with different initial hardness. This phenomenon significantly improves surface quality, diminishes surface defects caused by adhesion, and effectively reduces work hardening layers. The study also demonstrates that OME is a physical phenomenon closely related to the adsorption properties of organic catalytic agents and van der Waals interactions. Materials with higher initial hardness exhibit less pronounced OME due to a sufficiently high grain boundary density, impeding dislocation movement during shear deformation and causing a local stress increase at the free surface of the chip. This leads to a change in chip flow patterns, improving machining performance, analogous to the adsorption effect of organic catalytic agents.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00513-0

关键词: Organic monolayer embrittlement (OME), Cutting force, Chip morphology, Sinuous flow, Segmented quasi-periodic micro fracture flow

Abstract: In the traditional machining field, the addition of cutting fluid can appropriately reduce cutting forces, dissipate cutting heat, and facilitate the machining process. However, the use of cutting fluids has environmental implications. Recently, a phenomenon known as organic monolayer embrittlement (OME) has been proposed, which could address this issue. OME can reduce cutting forces, enhance surface quality, and improve machining performance without the need for cutting fluids, particularly noticeable in ductile metals like pure copper. This study conducted micro-cutting experiments on pure copper to investigate the microstructural features, cutting performance, chip flow patterns, and the effectiveness of OME. The results indicate that OME alters chip flow patterns from sinuous flow to segmented quasi-periodic micro-fracture flow, resulting in a 42% and 63% reduction in cutting forces for copper materials with different initial hardness. This phenomenon significantly improves surface quality, diminishes surface defects caused by adhesion, and effectively reduces work hardening layers. The study also demonstrates that OME is a physical phenomenon closely related to the adsorption properties of organic catalytic agents and van der Waals interactions. Materials with higher initial hardness exhibit less pronounced OME due to a sufficiently high grain boundary density, impeding dislocation movement during shear deformation and causing a local stress increase at the free surface of the chip. This leads to a change in chip flow patterns, improving machining performance, analogous to the adsorption effect of organic catalytic agents.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00513-0

Key words: Organic monolayer embrittlement (OME), Cutting force, Chip morphology, Sinuous flow, Segmented quasi-periodic micro fracture flow

Chao-Jun Zhang, Song-Qing Li, Pei-Xuan Zhong, Fei-Fan Zhang, Wen-Jun Deng. Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining[J]. Advances in Manufacturing, 2025, 13(2): 395-412.

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Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining

Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining

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