Distinct element simulation of ceramic machining: Material removal mechanism

This paper uses distinct element method (DEM) to simulate the material removal process in silicon nitride ceramics machining. Clusters are used in material modeling as an effort to model the microstructure of silicon nitride. Material damping is properly estimated for the dynamic cutting simulation. The simulation results demonstrate that DEM can reproduce many experimental observations of ceramic machining, including the initiation and propagation of cracks, chip formation process and material removal mechanisms. It is shown that material removal is mainly realized by brittle fractures caused by lateral cracks. Crushing-type material removal is also an important material removal mechanism in machining ceramics. Distinct element modeling is demonstrated to be a promising method to model the material removal mechanisms of ceramic machining.