Simulation of Nanometer-Scale Deformation of Metallic and Ceramic Surfaces

Abstract

The precision machining of metal surfaces and the ductile-regime grinding of ceramic surfaces are examples of fundamental cutting processes used in fabricating high-tolerance parts. Components with dimensional tolerances of a few tens of nanometers are currently being produced by direct machining with single-point diamond tools. Despite the ability to fabricate these parts, little is understood of the basic deformation mechanisms that determine how material is removed and deformed, how a tool-tip interacts with a workpiece, how induced surface and subsurface damage occurs, and how cutting tools wear.The key to solving these problems is a fundamental understanding of basic tribological processes such as surface indentation and scraping. Indentation experiments measure the mechanical response of a surface, the onset of plastic deformation, and material hardness. Macroscopic hardness measurements have been shown to correlate well with observed tensile yield strengths. Microscopic indentation studies, where the indentation size is smaller than the material grain size, show new and interesting phenomena. In the pioneering work of Gane and Bowden, no permanent penetration occurred until a critical load was achieved. They related this critical yielding to the theoretical shear strength in the metal, the strength required to create dislocations. Yielding of this sort has since been observed by many investigators.