Effect of Tool Geometry and Cutting Speed on Heat Generation in Nanometric Cutting of Copper Single Crystal

Metal cutting can be associated with high heat generation in the tool-chip interface zone and hence، the thermal aspects of the cutting process strongly affect the accuracy of the ultra precision machining. This study presents the effect of tool edge radius and cutting speed on heat generation and balance of energy in nanomachining process using three dimensional molecular dynamics simulation with Embedded Atom Method (EAM) metal potential energy. Results show whenever tool scratches the work material، atoms velocity of surface layers is increased dramatically، which influence kinetic energy and workpiece temperature. By increasing cutting speed to 400%، cutting forces are increased between 21-27%. Although tool forces is not increased considerably by cutting speed، a big fraction of potential energy، kinetic energy and heat transfer are remained in workpiece. So، workpiece temperature and temperature gradient is increased dramatically. Increasing cutting speed form 50 m/s to 200 m/s affect on temperature increment near machined surface from 300 C to 700 C which can affect the surface roughness. In addition، tool edge radius increases in contact area between tool and workpiece when tool forc is increased especially in trust direction. Consequently، temperature gradient is raised locally in chip formation area by tool edge radius.