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<p>Diffusion wear of tungsten carbide (WC) tools during aluminum alloy machining remains a challenge, primarily due to the adhesion and softening of the workpiece material. To elucidate the underlying atomic-scale mechanisms, this study calculated the Morse potential parameters between the tool and workpiece atoms and employed molecular dynamics (MD) simulations to investigate the diffusion wear process in the machining of 2024 aluminum alloy. The novelty of this study lies in the systematic analysis of how key cutting parameters (cutting speed, width, depth and rake angle) alter the distribution of cutting temperature and force on the tool through the evolution activities of atoms, thereby influencing wear. Simulation results demonstrate that these parameters significantly affect wear, whereas the tool relief angle has a negligible impact. Furthermore, our scientific contributions were validated through milling experiments, where the measured cutting forces and energy-dispersive spectroscopy (EDS) analysis of the tool wear zones confirmed the diffusion phenomenon and the accuracy of the simulation model. This research provides a theoretical foundation for optimizing cutting parameters to reduce tool wear and improve the surface quality of aluminum alloy machining.</p>

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Diffusion wear of WC tools during aluminum alloy cutting: a molecular dynamics study

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • Xueguang Li,
  • Zhaohuan Pang,
  • Junsheng Li

摘要

Diffusion wear of tungsten carbide (WC) tools during aluminum alloy machining remains a challenge, primarily due to the adhesion and softening of the workpiece material. To elucidate the underlying atomic-scale mechanisms, this study calculated the Morse potential parameters between the tool and workpiece atoms and employed molecular dynamics (MD) simulations to investigate the diffusion wear process in the machining of 2024 aluminum alloy. The novelty of this study lies in the systematic analysis of how key cutting parameters (cutting speed, width, depth and rake angle) alter the distribution of cutting temperature and force on the tool through the evolution activities of atoms, thereby influencing wear. Simulation results demonstrate that these parameters significantly affect wear, whereas the tool relief angle has a negligible impact. Furthermore, our scientific contributions were validated through milling experiments, where the measured cutting forces and energy-dispersive spectroscopy (EDS) analysis of the tool wear zones confirmed the diffusion phenomenon and the accuracy of the simulation model. This research provides a theoretical foundation for optimizing cutting parameters to reduce tool wear and improve the surface quality of aluminum alloy machining.