Effect of structure tool on nano-cutting surface integrity of single crystal γ-TiAl alloy via atomic simulation

To investigate the impact of microgroove geometry at the tool's flank face on the surface integrity of the workpiece, molecular dynamics simulation is utilized to establish a model of cutting single crystal gamma-TiAl alloy using various structured nanodiamond tools. The effect of groove shape on the surface integrity of single crystal gamma-TiAl alloys was investigated by analyzing mechanical properties, workpiece surface quality, and subsurface damage during the cutting process. The results show that non-structured tool cuts gamma-TiAl alloy with the highest cutting force, and the V-groove tool cuts with the lowest friction coefficient, which is favorable for the removal of single crystal gamma-TiAl alloy. Statistical atomic phase transitions during cutting confirmed that structured tools reduce subsurface damage, especially V-grooved tool reduce the generation of defective atoms. The circular arc grooved tool effectively reduces the subsurface temperature of the single crystal gamma-TiAl alloy workpiece by reducing the friction at the tool chip interface due to lower normal cutting force. In addition, the circular arc grooved tool cutting has stronger atomic flow and surface recovery ability compared with other tools, and smaller surface roughness can be obtained. Therefore, selecting a reasonable structured tool can effectively improve the machinability of single crystal gamma-TiAl alloy.