Molecular Dynamics Simulation of Effect of Rough Surface on Material Removal and Subsurface Defects During gamma-TiAl Machining

The molecular dynamics method was used to simulate the machining response of nanoscale gamma-TiAl. The rule-generated rough workpiece surface was used to study its effect on atom removal mechanism. The cutting process was investigated by varying the texture density and tool radius. Results show that the surface morphology of the workpiece has a non-ignorable influence on the generation of subsurface defects and the atom removal: the rough surface in the shear mode affects the generation of laminar fault shear zone. The increase in texture density increases the number of subsurface defects, and the integrity of the machined surface is different corresponding to different cutting patterns. The relative tool sharpness has an effect on the cutting mechanism and texture effects.