Numerical simulation of the influence of cutting parameters on the cutting process of ZrO₂ ceramics

Objectives: Research on ceramic processing primarily focuses on areas such as single abrasive grinding methods, processing mechanisms, processing efficiency, material removal mechanisms, and surface quality. However, research on ZrO₂ ceramic cutting processing is relatively insufficient. Therefore, the 3D cutting process of ZrO₂ ceramic workpieces was numerically simulated using the finite element simulation method. The study discusses the mechanism of chip removal, the dynamic change and distribution of stress, and the evolution law of cutting force under various cutting conditions. Methods: The 3D cutting process of ZrO₂ ceramic workpieces, under different machining parameters and tool parameters, was numerically simulated using the finite element simulation method. The cutting forces under various feed speeds and cutting depths were compared to explore the failure modes and material removal mechanisms of ZrO₂ ceramic during the cutting process. Results: The hard contact behavior between the cutting tool and the workpiece significantly affects the material removal process, leading to failure modes such as chip collapse, material cracking, and crack propagation. When the cutting depth is 200 μm or 250 μm, numerous cracks appear at the end edge of the workpiece and expand in the vertical cutting direction, resulting in significant fragmentation at the edge. An increase in cutting speed will causes fluctuations in stress and cutting force, but overall, there is no significant change in cutting performance. The radius of the cutting edge affects the formation of cracks in the initial cutting stage. As the edge radius increases, the length of the crack at the front end of the tool shortens, though the impact on cutting force is not significant. A negative tool rake angle during cutting does not induce cracks in the workpiece, and it leads to better machining quality. In addition, when the tool rake angle is 0 °, the maximum cutting force increases rapidly, but the cutting force variation is not obvious with increasing rake angle. Conclusions: As the cutting depth increases, the stress layer on the tool surface gradually expands from the tip to the front and rear cutting surfaces, and gradually increases. As the cutting depth increases, local cracks form at the cutting end of the workpiece and propagate downward. The position of maximum stress on the front cutting surface of the tool gradually increases with the increase in edge radius. However, the influence of the edge radius on the cutting force is relatively small. When cutting ZrO₂ ceramics with a tool featuring a negative rake angle, no internal cracks are caused, and good machining quality can be achieved.