基于实验与原子尺度模拟的金刚石刀具切削单晶硅材料去除机理研究

Material removal mechanism of diamond tool cutting single-crystal silicon based on experiments and atomic-scale simulations

  • 摘要: 为研究天然单晶金刚石刀具在单晶硅超精密切削过程中的材料去除机理,通过结合实验测试与分子动力学模拟,系统分析了刀具前角与主轴转速对切削性能和表面质量的影响。实验部分采用超精密车削与表面形貌表征技术,测量了不同前角与转速条件下的切削力、摩擦因数及表面粗糙度。模拟部分通过建立原子尺度切削模型,揭示了切削速度对原子相变与缺陷形成的影响规律。研究结果表明,0°前角刀具可显著降低平均切向力与摩擦因数,获得更优的表面光洁度。主轴转速的提升可有效降低表面粗糙度,改善表面质量。模拟结果进一步显示,高切削速度能抑制高压相形成、减少缺陷原子。基于实验与模拟数据,通过高斯过程回归与Bootstrap重采样方法构建预测模型,实现了切削性能趋势分析与不确定性评估。研究结论为单晶硅超精密加工参数优化与表面质量控制提供了理论指导与数据支撑。

     

    Abstract: To investigate the material removal mechanism of single-crystal silicon during ultra-precision cutting with a natural single-crystal diamond tool, experimental testing was combined with molecular dynamics simulations to systematically analyze the effects of tool rake angle and spindle speed on cutting performance and surface quality. In the experimental procedure, ultra-precision turning and surface characterization techniques were employed to measure the cutting force, friction coefficient, and surface roughness under different rake angles and spindle speeds. In the MD simulation, an atomistic cutting model was established to reveal the influence of cutting speed on atomic phase transitions and defect formation. It is indicated that a 0° rake angle tool significantly reduces average tangential force and friction coefficient, achieving superior surface finish. Increased spindle speed effectively decreases surface roughness and improves surface quality. Simulation results further demonstrate that higher cutting speeds suppress high-pressure phase formation and reduce defect atoms. Predictive models were constructed based on experimental and simulation data using Gaussian Process Regression and Bootstrap resampling for performance trend analysis and uncertainty assessment. Theoretical guidance and data support for optimizing process parameters and controlling surface quality in ultra-precision machining of single-crystal silicon are provided.

     

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