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agreed that the tool presents a large negative rake According to Komanduri et al [35], it is the severe negative rake angle, which provides the necessary hydrostatic pressures for enabling plastic deformation of the workpiece material beneath the tool radius to take place However, this should not be confused with the type of plastic deformation with regard to concentrated shear planes, which occurs ahead of the tool in the case of conventional machining of metals with positive rake tools Plastic deformation in the case of brittle materials with large negative rake tools is energy intensive and inefficient compared to machining metals with positive rake tools
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Fig 336: (a) A sharp +ve rake conventional cutting tool with the edge radius being equal to the depth of cut or
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even smaller, (b) a very large ve rake abrasive grain used in grinding (c) a 0o rake diamond tool, behaving as a ve rake tool, used in ultra-precision machining at small depths of cut, and (d) indentation sliding [35]
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In summary, brittle material is removed in different ways depending on the size and the density of the defects in the material such as flaws and cracks, and the size of the stress field When the stress field brought about by a grain cutting edge is smaller than the defects, material will be removed mostly by plastic deformation On the other hand, when the stress field is larger than those defects, a localized brittle microfracture plays an important part Although an extremely high hydrostatic pressure is a prerequisite for plastic deformation to occur in brittle materials, this hydrostatic pressure can be obtained immediately by decreasing the undeformed chip thickness and/or tool rake angle, instead of any externally exposed pressure Plastic deformation that has taken place during machining is commonly termed as ductile regime/mode machining
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351 Ductile Mode Machining of Hard and Brittle Materials
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Machining of hard and brittle materials always poses problems and is uneconomical due to short tool life, low material removal rate, poor surface quality and high damage to the surface near layer [39] However, under certain controlled conditions, it is possible to machine brittle materials using single- or multi-point diamond tools so that the material can be removed by plastic flow, leaving a crack-free surface This condition is called ductile mode machining According to this concept, all materials will deform plastically if the scale of deformation is very small during machining Several terms are used to indicate the plastic deformation phenomenon on machined surfaces such as ductile
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Mechanics of Materials Cutting
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regime turning [40], ductile mode machining [41], ductile machining [42], ductile regime grinding [43], microcrack-free or damage free grinding [30] and partial ductile mode grinding [44][45] It has been thought that a material is less brittle below a certain depth of cut value; this has therefore given rise to the term ductile mode cutting/grinding Under this machining condition, it is feasible to remove material without initiating a residual crack at or near the surface leaving essentially microcrack-free surfaces When a mixture of plastic deformation and fractures appears on the ground surface, the term partial ductile mode grinding is preferably used instead of semi-ductile, as the exact number of ductile areas is unknown Miyashita [46] used the term microcrack machining to indicate the transition from brittle to ductile machining as shown in Figure 337 A better term to use may be partial ductile machining as the surface consists of a mixture of fracture and ductile modes To maximize ductile mode machining, the grain size and the material removal rate must be very small, and the height distribution of the cutting edges also must be extremely tight as compared to the abrasive distribution height used in conventional grinding, lapping, honing, and superfinishing processes With certain materials, it is possible to machine almost 100% in the ductile mode condition using rigid ultra-precision machines, whereas only the partial ductile mode condition is achievable by conventional grinding due to the random orientation of abrasive grains on the diamond wheels
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Fig 337: Conventional machining processes versus the nanogrinding process [46]
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