Wear Mechanism and Wear Suppression at the Nanoscale of Diamond Tools in Cutting CFRP

doi:10.3901/JME.2025.07.181

Abstract

Abstract: In the continuous processing of large-size high-performance carbon fiber reinforced polymer (CFRP) components, the problem of insufficient wear resistance of diamond tools is still prominent. The multi-scale wear mechanism is extremely complex including the interaction among the multiple nano-scale carbon structures and the interaction between the cutting edge and fiber at micro-scale, which makes the wear suppression method for such tools become a difficult problem in the field of advanced composite machining. Therefore, starting from the nano-scale, a molecular dynamics model which can simulate the sliding process on the carbon fiber by diamond at the nano-scale is established for the first time. The basic experiment of cutting CFRP tube by the diamond coated tool is designed and carried out. The failure behavior, wear process and wear suppression method of the diamond at the nano-scale in cutting CFRP are studied. The results show that the micro-scale wear of diamond is mainly caused by the mechanical interlocking of carbon fibers and the interaction bonds, and the structural distortion at the flank face before the initial wear stage, the bonds formation of the interfacial bonds, and the transformation of the sp3 carbon structure to the sp2 carbon structure. Rapid wear stage is dominated by the peeling of small atomic clusters at the flank face (the transgranular fracture of the surface carbon structure) and the peeling of a larger range of atomic clusters at the flank face caused by fracture along the <111> crystal plane (intergranular destruction of near surface carbon structure). In the nitrogen and hydrogen environment, hydrogen ions tend to form carbon-hydrogen bonds on the surface of diamonds, which blocks the formation of carbon-carbon bonds between diamonds and carbon fibers, and the structural transformation and destruction degree caused by carbon-carbon interface bonds are reduced. Combined with Raman spectroscopy, it is confirmed that the nitrogen-hydrogen environment can reduce the wear of diamond-coated tools at the source. The above research can provide a theoretical basis and reference for the wear suppression of diamond tools for cutting CFRP.

Key words: cutting of CFRP, diamond tools, wear mechanism, nanoscale, suppression

CLC Number:

TG711

SU Youliang, WEN Tianhao, MENG Zhijian, LIU Junqiang, ZHANG Bo. Wear Mechanism and Wear Suppression at the Nanoscale of Diamond Tools in Cutting CFRP[J]. Journal of Mechanical Engineering, 2025, 61(7): 181-197.

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http://www.cjmenet.com.cn/EN/Y2025/V61/I7/181

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