Simulation and optimization of surface roughness and cutting force in dynamic ploughing process of single crystal copper using molecular dynamics method

Surface roughness is one of the most important characteristics in nanomachining products. One of the parameters that always has a great impact on the surface quality is the forces caused by the nanocutting process. In this research, using molecular dynamics simulation in LAMMPS software, the process of dynamic nano ploughing of single-crystal copper workpiece by a diamond tool is investigated. The effect of parameters of dynamic nano- ploughing process such as depth of cut, amplitude and frequency of cutting tool vibration on cutting force and surface roughness has been investigated by calculating average roughness. Also, in order to more closely examine the effect of parameters and their interaction on each other, Taguchi method has been used to design experiments. The simulation results show that the characteristics of cutting depth, amplitude and frequency of cutting tool vibration have the greatest effect on surface smoothness and cutting forces, respectively. Based on the presented results, it has been determined that the surface roughness can be improved in different machining conditions based on the selection of parameters, and it is necessary to check their conditions together well before selecting these parameters. Also, using Taguchi method, the optimal values of dynamic ploughing parameters were obtained to achieve the best surface smoothness and the lowest cutting force in certain dimensions as described by DOC=2.5 , R=0.1 and ω=50 KHz.