Investigating micro-cutting mechanism of glow discharge polymer based on material properties and removal behaviors analysis

Glow discharge polymer (GDP) is the unique artificial material for the target balls in Inertial Confinement Fusion tests, while its practical micromachining such as the fabrication of microstructure on material surfaces keeps challenging due to its unclear micro-cutting mechanism. Hence, this paper seeks to investigate the micro-cutting mechanism of GDP from the perspective of the material flow and cutting energy. To achieve it, the energy conservation equation of three cutting modes triggered by different ratios of uncut chip thickness to the tool cutting edge radius (RTS) was established based on cutting deformation behaviors. Meanwhile, the diamond cutting tests and the FEM simulation at different RTS were developed. The experimental observation of cutting forces and specific cutting forces verified the evolution of three cutting modes, including shearing, shearing-ploughing and ploughing in the micro-cutting of GDP with the decrease of RTS. Next, from the change of the node displacement vector observed from the simulated results, it can be seen that the real-time material flow behavior during micro-cutting of GDP varies obviously with the evolution of cutting modes. Besides, the fracture toughness G_c, and the energy dissipation of different cutting modes were analyzed. The proportion of the energy spent on material fracture (G_c=9.95 N/mm) is the largest one in shearing and shearing-ploughing modes, while in ploughing mode, the material plastic deformation consumed the most energy. The above results reveal the specific material properties and removal behaviors of GDP and contribute to optimizing the machining strategies for the practical micromachining of microstructures on material surfaces.