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The cutting depth on this sample was 50 nm.
The depth of subsurface deformed layer increases with cutting depth, proportionally, and basically remains unchanged when the cutting depth reaches over 6 nm.
As the cutting depth increases, the number of amorphous atoms near the abrasive particles also increases.
A smaller cutting depth means less material deformation, and therefore results in a weaker boundary effect.
It can be seen that with the decrease of cutting depth the resultant cutting force decreases.
At the same simulation step, cutting depth increases with increasing the cutting angle.
Furthermore, the cutting depth increment has direct relations with the atomic interactions.
Because of finite stiffness of grinding system, grinding force will cause the tool deflection (the difference between actual cutting depth and nominal cutting depth).
Increasing tool posture angle decreases the grain cutting depth to the critical cutting depth from brittle cutting to ductile cutting, but it increases the risk of tool interference.
During milling, the cutting depth constantly decreases, thus, to obtain the correct cutting depth, the model considers movement of the tool in a vertical direction.
A plot of cutting force fluctuations versus the cutting depth follows a sigmoidal curve.
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Justyna Jupowicz-Kozak
CEO of Professional Science Editing for Scientists @ prosciediting.com