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<p>High-entropy alloys (HEAs) exhibit excellent machining performance due to their compositional diversity. In nanocutting, grain refinement can further enhance the material’s plastic deformation capacity and surface integrity. This study uses molecular dynamics (MD) simulations to analyze the microplastic deformation mechanisms of polycrystalline FeCoNiCrCu HEA during nanocutting, focusing on the influence of different grain sizes. By constructing polycrystalline and nanocutting models, we examine the effects of grain size on cutting forces, surface morphology, dislocation defects, and stress distribution. Results indicate that larger grains (10.47&#xa0;nm) allow dislocations to propagate over longer distances, leading to a more uniform plastic deformation. In contrast, smaller grains (6.49&#xa0;nm) result in stronger boundary obstruction of dislocations, leading to local accumulation, narrower shear zones, and enhanced resistance to deformation. Reducing grain size increases dislocation density and stress concentration in the cutting zone, amplifying sub-surface defect evolution. Moreover, HEAs with smaller grains demonstrate stronger resistance to deformation and reduced cutting forces during the cutting process. This research provides insights into the micro-behavior of HEAs in nanomanufacturing and guidance for precision machining processes of high-performance materials.</p>

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Study on the effect of grain size on the nanocutting mechanism of polycrystalline FeCoNiCrCu

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Ping Zhang,
  • Guohong Li,
  • Xiaomin Jiang,
  • Xue Chen

摘要

High-entropy alloys (HEAs) exhibit excellent machining performance due to their compositional diversity. In nanocutting, grain refinement can further enhance the material’s plastic deformation capacity and surface integrity. This study uses molecular dynamics (MD) simulations to analyze the microplastic deformation mechanisms of polycrystalline FeCoNiCrCu HEA during nanocutting, focusing on the influence of different grain sizes. By constructing polycrystalline and nanocutting models, we examine the effects of grain size on cutting forces, surface morphology, dislocation defects, and stress distribution. Results indicate that larger grains (10.47 nm) allow dislocations to propagate over longer distances, leading to a more uniform plastic deformation. In contrast, smaller grains (6.49 nm) result in stronger boundary obstruction of dislocations, leading to local accumulation, narrower shear zones, and enhanced resistance to deformation. Reducing grain size increases dislocation density and stress concentration in the cutting zone, amplifying sub-surface defect evolution. Moreover, HEAs with smaller grains demonstrate stronger resistance to deformation and reduced cutting forces during the cutting process. This research provides insights into the micro-behavior of HEAs in nanomanufacturing and guidance for precision machining processes of high-performance materials.