A study on the effect of double-tip inclined angle on micro-scratching process using smooth particle hydrodynamic method

Abstract

Multi-tip micro/nano-scratching technology has been widely used in precision manufacturing. In this study, the smooth particle hydrodynamic based on micro-scratching model is proposed to study the effect of double-tip inclined angles on such a scratching process. A series of simulations were conducted with the double-tip tilting with 0°, 5°, and 10° on the oxygen-free copper surfaces. In this article, the formation of burrs and scratching forces was illustrated and analyzed based on the simulation results. It is noted that when the double-tip tilted, the burrs generated more and side flows curled seriously during scratching process. With an increase in the scratching distance, more burrs generate on both sides of the groove. The tangential, thrust, and lateral forces are all affected by the extrusion of side flows and the protrusion in middle. Moreover, the scratching forces of tangential and thrust showed that the double-tip scratching process can be divided into three stages: initial scratching stage, transition scratching stage, and stable scratching stage. During transition scratching stage, the most violent scratching forces generated in the condition of the double-tip tilting with 10°.