On the Aptness of Material Constitutive Models for Simulating Nano-Scratching Processes

Abstract

The simulation of nano-scratching on metallic substrates using smooth particle hydrodynamics (SPH) has been attempted by researchers in recent years. From a review of the existing SPH simulations of nano-scratching processes, it was found that mainly two different material constitutive models (i.e., the Johnson–Cook model and the elasto-plastic model) were employed to describe the material flow. In the majority of these investigations, the Johnson–Cook model was employed to characterise the stress flow of the material subjected to scratching. A natural question remains as to which material constitutive model is preferable for the SPH modelling of nano-scratching when quantitatively predicting the process outcomes. In this paper, a quantitative comparison of material responses during the nano-scratching of copper is reported when the process is simulated using SPH with two different constitutive material models, namely the Johnson–Cook and the elasto-plastic models. In particular, the simulated cutting and normal forces as well as the machined topography using both approaches are compared with the experimental work reported in the literature. The SPH-based simulation results in this paper are investigated based on the following three aspects: (a) cutting and normal forces with different material models and depths of the cut, (b) the effect of the cutting speed on forces and its dependence on adopted material models, and (c) the effect of adopted material models on the surface topography of machined nano-grooves. The SPH simulation results showed that using the Johnson–Cook material model, cutting and normal forces were closer to the experimental data compared to the results obtained with the elasto-plastic model. The results also showed that the cross-sectional profile of simulated nano-grooves using the Johnson–Cook model was closer to the experimental results. Overall, this paper shows that the selection of the Johnson–Cook model is preferable for the SPH modelling of the nano-scratching process.