Optimization Strategy for Milling of Copper Using Molecular Dynamics Modelling

This research work reviews the milling of copper using molecular dynamics (MD) simulation to study underlying core mechanisms experienced during the cutting process. The inconsistency in the machinability of one material relative to another is based on both physical and mechanical properties it possesses. Improved studies of the sub-surface mechanismsoccurring during cutting are required as it depicts a clearer picture for condition prediction. In this study, the classical molecular dynamics simulation was performed to investigate the deformation in the machining of copper. This approach employs the use of the Morse potential to represent the interatomic forces between the atoms of the copper work piece and the tool as well as the EAM potential between work piece atoms. Owing to the malleable and ductile nature of copper, the influence of some machining conditions on the mechanical properties was also analysed. Conditions such as thermodynamic form, energy and temperature were observed. Relations to strain effects and dislocations within the simulated copper block have been associated to force variation obtained during milling. This is seen from the gradual increase in energy and force correlations during simulations. Representation of the actual milling process was done to validate the results obtained from the simulation. From the results, it was found that the MD simulations provided an adequate representation of the sub-surface and surface effects experienced in the milling of copper. Further analysis into the tool chips and chip formation was also performed.