Influence of Mechanochemical Effect on Deformation Behavior of Aluminum Cutting Layer Under Electrostatic Catalysis

The application of the mechanochemical effect as a means to enhance the cutting performance of gummy metals represents a pioneering approach in machining. In this study, we introduce static electricity to improve the machinability of aluminum under the mechanochemical effect. This method involves applying n-propanol to the workpiece surface under the influence of static electricity before the machining. Various deformation behaviors of aluminum cutting layers during orthogonal cutting are analyzed using high-speed in situ imaging and digital image correlation. Furthermore, the synergistic effect of static electricity on mechanochemical effect is verified by combining cutting force and machined surface quality measurements. The results show that the use of n-propanol under static electricity results in reduced cutting deformation, decreased strain rate and a more uniform strain distribution in the primary shear zone compared to surfaces solely coated with n-propanol. Consequently, this reduced deformation mode induces chip thinning and lowers cutting force by about 60% and 10%, respectively. The workpiece surface exhibits improved smoothness, with material pull-outs and pits nearly disappearing. It is found that these phenomena can be attributed to electrostatic catalysis, where a large number of electrons catalyze the reaction between active alcohol molecules and aluminum, forming a richer alkoxide film that enhances the mechanochemical effect.