1 Study on Fracture Mechanism of Rock Cutting 2 Xin Wei, Chengyong Wang and Hui Yuan 3 4 Faculty of Mechanical & Electronic Engineering, Guangdong University of Technology, Guangzhou 510090 P. R. China 5 Keywords: Rock, Granite, Diabase, Cutting mechanism 6 7 8 9 10 11 12 Abstract. This paper presents a review of the authors’ investigation in the cutting processes of diabase and granite. The formation of crushed zone and the propagation of microcracks and cracks under different cutting conditions have been observed in detail by means of a workshop microscope and a polarization microscope. The fracture mechanism is analyzed by measuring the cutting strain field using laser speckle interferometry and comparing the fractography of the cutting chips with those of the samples of tensile test and shear test. The cutting mechanism models of diabase and granite are proposed respectively. 13 Introduction 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Rock cutting has been widely used in the fields of machining natural slabs, basic components of precise instruments, etc. Rock cutting processes have been studied since 1950’. Several physical models of rock cutting mechanism have been proposed based on experimental study and finite element analysis. It is well known that the process of rock fracture under indentation generally includes the following stages: building up of the stress field, formation of an inelastic deformation zone or a crushed zone, chipping and crater deformation of surface, and formation of subsurface cracks [1, 2, 3]. But there are some differences between the research results relating to the formation of crushed zone and the formation and propagation of cracks and chipping. Based on coal cutting process, Evans (1958) supposed that the chipping crack is formed by the action of tensile stress [4]. Gray (1982) considered that the chipping trajectory takes a logarithmic contour and the initial cracks are formed by shear stress [5]. Hood (2000) indicated that the cutting tool (either a drag bit or an indenter) induces tensile cracks in the rock and these cracks propagate to form fragments or rock chips, and the wedging action of sharp drag bits produces tensile stress in the rock in a fairly direct manner [6]. On the other hand, some researchers think the chipping crack is a mixed tensile and shear mode crack [3]. Regarding to the formation of crushed zone, Lindqvist (1983) concluded from the indentation experiments that the crushed zone in marble is formed with inelastic deformation by the shear action and that in granite or sandstone is characterized by brittle fracture [7]. Zeuch (1985) indicated that fractures are nucleated in the rock in advance of the cutter tip and all of the large chips had an apparently crushed, powdered region at the trailing edge of the fragment which might represent the region of intense triaxial compression [8]. Some researchers consider that the crushed zone, under the load of an indenter, forms before the formation of the cone crack and its formation results from the accumulation of crushed rock between the tool and the loaded rock; others suppose that the formation of cone cracks precedes the formation of the zone of the crushed rock [3]. Kesteren (1993) hypothesized that the size of the crushed zone is determined by bifurcation of a shear crack into a tensile crack under mixed mode loading conditions, which was verified by using numerical tools [9]. The crushed zone is an energy intensive zone and transfers the cutting load. So, its size determines the cutting forces and geometry of the chip. The formation of cracks or chipping and crushed zone depends on the properties of rocks. Some physical mechanisms applied to plastic or porous rocks can’t be used to describe the cutting process of brittle hard rocks. Here we review a number of our investigations in the cutting processes of diabase and granite. The objective is to propose the mechanisms of cracks formation and propagation and the characters of the crushed zone based on experimental observation and 47 48 49 50 51 52 53 theoretical considerations. The cutting processes of diabase and granite under different cutting conditions were observed by a workshop microscope, and the cutting experiments of granite were carried out and observed under a polarization microscope as well to obtain detailed information on the formation and development of microcracks. The stress fields of the rocks in cutting processes were measured by laser speckle interferometry method. The fracture mechanism under the cutting action was also analyzed by comparing the topographies of the chips with the rock fractographies of tensile test and shear test samples. 54 Experiment 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 The experiments were conducted to observe and analyze the cutting processes of diabase and granite under different cutting conditions, respectively. The diabase with shore hardness of 79, compress strength of 0.25 GPa and doleritic texture was cut by carbide K20 cutting tools with rake angle of –10°, 0° and 10°, and clearance angle of 6°. The cutting processes were observed with a microscope from the side view of the workpieces. The cutting parameters used in cutting the diabase included: the depth of cut 0.08mm, 0.2mm, 0.4mm, 0.8mm, 1.2mm; cut width 7.5mm, manual feed. The cutting processes of granite were conducted in the following two ways. The macro cutting processes on a planner by carbide tools were observed with a workshop microscope. The depth of cut of 0.08mm, 0.4mm and 0.8mm, and cutting width of 0.6mm were used. The cutting tools have a rake angle of -10°, 10° and clearance angle of 6°. The cutting processes of granite were also observed with a polarization microscope on a micro-feed cutting device by PDC cutters to assess the micro-process in cutting granite, especially the effects of mineral properties on granite cutting mechanism. The cutting parameters include: rake angle -10°, -5° and 5°; a clearance angle 8°; and the depth of cut 0.05mm ~0.1mm, manual feed. Five kinds of granite with different mineral composition and grain size were studied. The granites consist mainly of the minerals of feldspar, quartz, plagioclase and metabiolite. 72 Results and Discussion 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 Cutting Processes of Diabase. Features of the Cutting Process of Diabase. The typical cutting process of diabase includes the following three stages. (1) When the cutting tool contacts the diabase, powder chips form and some small lateral cracks occur, leading to the crater in the contact zone around the tool tip, as shown in Fig.1 (a). The powder chips flow away from the contact zone with some small chippings as the cutting tool being fed. (2) The diabase in the contact zone near the tool tip becomes compact under the press of the cutting tool. Simultaneously, the rock in the zone is crushed and accumulated (see Fig.1 (b)). (3) The size of the crushed zone increases and transfers the cutting force from the cutting tool. The dominating crack, initiating from the contact zone above the tool tip, propagates along the upper boundary of the crushed zone and then towards the free surface of the workpiece, which leads to chipping, as shown in Fig.1 (c) and Fig.1 (d). The actual depth of cut in this case is larger than the mean depth of cut. The crushed zone has the shape of a wedge. The features of the cutting process described above are more apparently when cutting at larger depth of cut or negative rake angle [10, 11, 13]. Crushed Zone in Diabase Cutting Process. It can be concluded, based on the experimental observation of the diabase cutting process, that the crushed zone forms after the lateral crack initiating at the contact point with the tool tip intersect with the crack initiated above the tool tip. It forms and grows repeatedly. The crushed zone transfers the cutting loads acting as a cutting tool when it becomes large. The real rake angle, therefore, is about 70° for the cutting tool with rake angle of –10° and 50° ∼ 60° for the other cutting tools. The depth of cut has no effects on the real angle [10, 11, 13]. Powder chips Powder chips Cutting tool Cutting tool Powder chips Cutting tool ap Main crack Crushed zone Lateral crack 94 95 (a) Chip (b) (a) The formation of powder chips and lateral crack (b) The formation of crushed zone (c) The propagation of main crack and chipping (d) Photography of the cutting process of diabase (γ0= -10°, α0=8°, ap=8mm) Main crack 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 (c) Crushed zone Cutting tool 96 97 98 99 100 101 102 103 apover 50µm (d) Fig.1 The cutting process of diabase (ap: depth of cut; apover: depth of over cut) Fig.2 shows SEM observation of the material in the crushed zone. It can be seen that the crushed zone consists of slice, granular minerals with average diameter < 4.8 m. There are no obvious boundary cracks in the crushed rock, which means that the crushed rock is compacted. 5 µm 50 µm 50 µm (a) Topography of crushed zone (b) Fractography of tensile test (c) Fractography of shear test Fig.2 SEM observation of crushed zone and samples of diabase The topography of the crushed zone (Fig. 2(a)) shows similar features to the fractography of the tensile test sample of diabase (Fig.2(b)). This means that the rock in the crushed zone is cracked and crushed mainly by the action of tensile stress. The crushed rock is compacted under the press action of the cutting tool due to the existence of mineral defects such as porosity, cleavage plane, etc. in the diabase. The crushed rock doesn’t adhere to the rake face of the cutting tool. The size of the crushed zone is affected by the depth of cut and rake angle of the cutting tool. With the increase of the depth of cut, the contact length between the crushed zone and the rake face increases. And the real rake angle decreases with the increase of the rake angle. The Formation and Propagation of Cracks in Diabase Cutting Processes. (1)Mechanism of the Formation and Propagation of Cracks. The typical formation and propagation of the cracks in cutting diabase can be described as follows (See Fig.1) [10,13]. The dominating crack generates above the tool tip. Continuous feed of the cutting tool causes it to propagate along the upper boundary of the crushed zone to the point lower than the depth of cut resulting in over cut. Then the crack propagates again towards the free surface, which causes the formation of chipping and crater on the surface of the workpiece. The crack trajectory takes generally on an arc contour. Some new microcracks may occur and develop at the direction parallel to the surface. These cracks may stop propagating or change their direction if they meet some initial defects in the rock. 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 The cutting strain fields of the diabase were measured by means of laser speckle interferometry to understand the reasons causing the fracture of the rock in cutting processes [10,12]. As shown in Fig.3, a high tensile strain concentration zone and high shear strain concentration occur above the cutting tool tip respectively. It can be concluded that the initial crack is caused mainly by the tensile stress because the maximum normal strain is larger than the maximum shear strain and the tensile strength of the rock is much less than the shear strength. It conforms to some researchers’ results of theoretical analysis about indentation processes theory of brittle materials that high compressive strain zone occurs near the cutting tool tip. In spite of some errors on the measurements of the rock displacement and on the calculation of the strain field, the maximum gradient direction of normal strain conforms to the crack trajectory. It is proved by the measured results of strain field that the cracks form mainly by the action of tensile stress and propagate along the maximal gradient direction of the normal strain. The reasons causing the fracture of the rock in cutting diabase can be further verified by comparing the topographies of cutting chips with the fractographies of the tensile and shear test samples. 33 Tool 29 23 20 Fx 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 19 Fy 16 15 13 -7 28 15 5 8 10 12 6 9 14 18 36 40 -9.6 12 -5 -3 -8.6 -5.6 -7.6 -6 -6 36 9 34 23 25 20 15 30 12 20 20 16 12 16 10 11 17 13 7 24 15 23 23 13 17 19 (a) (b) (c) (d) Fig.3 Cutting strain field of diabase (+: tensile strain; -: compressive strain) (a) Main strain field ε1(Fx=740N, Fy=252N) (b) Main strain field ε1(Fx=1.04kN, Fy=390N ) (c) Main strain field ε2(Fx=1.04kN, Fy=390N) (d)Max. shear strain field ε1(Fx=1.04kN, Fy=390N ) The main mineral of the diabase is pyroxene with cleavage plane {110}. The aggregate shows half-idiomorphic and xenomorcleaphic granular. Other minerals of the diabase include column or granular epidote with cleavage plane {110} and scale-like chlorite aggregate with cleavage plane {001}. As shown in Fig.2 (b), the tensile test sample is observed mainly with cleavage fracture and grain breakage. The cracks form often along the mineral crystalline cleavage. Because of defects, the fracture develops not only along one but several parallel cleavage planes in different height, which causes the fractography to show river pattern and step pattern. The grain breakage pattern observed may occur along the crystalline boundary or/and within a grain. The cracks propagating along the crystalline boundary may cause the whole grains to be dislodged. If the strength of crystalline grain is less than that of the crystalline boundary, the grain will is broken locally. The shear test samples are shown mainly the topographies with flat pattern and striation pattern, as shown in Fig.2 (c). Fig.4 shows the typical cutting chips of the diabase, which are divided into three segments. The first segment, the formation and initial propagation of the crack, and the third segment, the final propagating stage toward the free surface, reveal the same characters with the fractographies of the tensile test samples. On the other hand, in the second segment, the chip was found with the features not only of tensile fractography but also of shear fractography. It means that the crack forms and then propagates by tensile stress, in its following process, the mixed action of tensile and shear stress causes the crack to develop [10,13]. It is the tensile crack propagation again to cause the chipping of the crack finally. This conclusion conforms to that by the cutting strain field in Fig.3. (2) The Factors Affecting the Formation and Propagation of Cracks in Diabase Cutting Process. The formation and propagation of cracks in the cutting process of diabase are influenced by the cutting condition and workpiece property. When increasing the depth of cut ap, the depth the crack propagates down into the interior of the workpiece increases, resulting in an increase in the depth of over cut apover. apover is almost proportional to ap in the case where the rake angle is -10°.When ap is small, apover under positive rake angle is larger than that under negative or 0° rake angle. On the contrary, apover under positive rake angle are smaller than that under negative or 0° 172 173 174 175 176 rake angle when ap is large. The formation and development of cracks are affected by the defects in the diabase as well. 50µm 50µm (a) 50µm 50µm (b) (c) Cutting direction I 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 II (a) Topography of segment I (b) Topography of segment II (c) Topography of segment III (d) outline of cutting chip III (d) Fig.4 Fracture features of diabase chip Cutting Processes of Granite. The Characteristics of Granite Cutting Processes. Fig.5 and Fig.6 show the cutting processes of granites observed by means of a microscope and a polarization microscope, respectively. When the cutting tool tip contacts and presses the rock, the rock is crushed and compacted at once within a small area in front of the tool tip, as shown in Fig.5and Fig.6 (a). Some of fine powder chips may be dislodged and erupt from the contact area at the same time. As the process advances, the crushed zone becomes large, and one or two cracks and lots of microcracks form, which initiate from the boundary of the crushed zone (See Fig. 6(b)). Continuous application of the cutting force causes the cracks and microcracks to propagate. One of the cracks develops toward the free surface, resulting in chipping and a crater on the surface of the workpiece, as shown in Fig.6(c). The other cracks and mincrocracks stop developing. The similar process has been found for all the granites under different cutting conditions [10, 11,13-17]. Fig.5 Cutting granite observed with workshop microscope (Fine grain granite, γo= 10°, αo=8°) Regarding to the cutting processes of fine grain granite, the chip pattern changes usually from powder chip to granular and fracture chip as the depth of cut increases. The effects of cutting speed on the cutting process can be neglected. The cutting processes of coarse grain granite are more remarkably affected by the mineral properties. The fracture chips are formed easier in cutting coarse grain granite than fine grain granites. 0.2mm 0.2mm 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 0.2mm (a) (b) (c) Fig.6 The cutting process of granite observed with polarization microscope ( Fine grain granite, ap=0.1mm, γo= -5°, αo=6°, cutting direction“ ←”) The Properties of the Crushed Zone. The crushed zone is formed by the press of the cutting tool rake face and tip. Its shape and size are determined greatly by the properties of mineral material being cut such as grain size, composition, the direction of cleavage plane and boundary, etc. The crushed zone causes granular chips generally. The crystalline grain can be seen in a SEM topography, as shown in Fig.7. Many thinner pieces, parted and micro-cavities are found as well in the crushed zone. The crushed zone is formed under the action of the tensile stress. There are some differences between the crushed zones formed in cutting diabase and granite. It has no regular shape and size because the granites are very brittle and hard. Once the crushed zone forms, it transfers the cutting force by means of the force balance obtained by the friction and insertion between the granular chips. When the elastic energy that is accumulated in this zone excesses some limits, the balance is broken. This leads to the cracks to propagate in an instable situation and to the formation of chipping. 0.5mm Fig.7 Topography of crushed zone in granite The Formation and Propagation of Cracks and Microcracks. In the cutting processes of granite, one or two cracks form under the action of tensile stress after the formation of the crushed zone and lots of microcracks may form somewhere around the crushed zone at the same time. The cracks and microcracks are very straight with very thin tip. This means that the cracks and microcracks are formed by the cutting stress. The cracks and microcracks propagate stably with the progress of cutting, as shown in Fig.6. The main crack that is perpendicular to the largest tensile stress propagates faster than others. The propagation of cracks and microcracks shows the feature of a tensile crack. When large depth of cut is used, the formation and propagation of the crack are dominated by the cutting stress [10, 16, 17]. Lots of initial defects existing in the rock cause the concentration of stress and change the stress distribution locally. With a decrease in the depth of cut or a increase in grain size of the granite, the effects of mineral properties such as composition, grain boundary, cleavage plane, initiate cracks, etc. on the propagation of cracks and microcracks increase. The propagating processes of the cracks are dominated by the mineral properties when the depth of cut is smaller than 0.08mm, as shown in Fig. 8 [16, 17]. Effects of Mineral Properties on the Propagation of Microcracks. The cutting processes under the condition of small depth of cut ( ≤ 0.1mm) are discussed here to get detailed information 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 on the micro cutting process of granite. In this case, the cutting process progresses within a single mineral grain normally. The propagation of microcracks and cracks is dominated greatly by the properties of the mineral grain being cut. Fig.8 shows the propagating process of cracks and microcracks when a feldspar grain is being cut. The crushed zone is uneven, or stepped. The microcracks are formed after the formation of the crushed zone with the grain. The cracks and micrcocracks usually develop along the crystal lattices of the feldspar grain in two right directions, as shown in Fig.8(c). The crater on the cut surface and the residual microcracks take the contour of a right triangle. The cracks and microcracks in a feldspar grain grow easier than those in a plagioclase grain especially in a microline grain.Fig.9 shows the shape of the crushed zone and the propagation of microcracks and cracks as a quartz grain being cut. The quartz grain is very hard and has no cleavage plane. The microcracks and cracks induced by the press of the cutting tool, therefore, propagate in the path of shell, resulting in a shell-like crater and residual microcracks in the rock, as shown in Fig.9 (b). Most of quartz grains reveal granular cracks. Besides these cracks and microcracks, the intergranular crack is often formed along the boundary of the quartz grain when the depth of cut is large. If a quartz grain locates in front of the mineral grain being cut, an intergranular crack is usually formed on the boundary. The quartz grain is even dislodged when it is small or the cutting force is large. 0.2mm 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 0.2mm 0.2mm (a) (b) (c ) Fig.8 The propagation of crack5 in a feldspar grain ( Middle size granite, ap=0.07mm, γo= -5°, αo=6°, cutting direction“ ←”) 0.2mm 0.2mm (a) (b) Fig.9 The propagation of crack in a quartz grain ( Middle size granite, ap=0.08mm, γo= -5°, αo=6°, cutting direction“ ←”) When the cleavage plane of a metabiolite grain is almost perpendicular to the cutting direction, the grain will be compacted after distorting, which leads to a formation of crushed zone and cracks in two directions, that is, the direction parallel to and perpendicular to the cleavage plane, as shown in Fig. 10(a). The cracks and microcracks propagate along cleavage plane and its perpendicular plane alternatively, resulting in uneven fracture chips and cracks, as shown in Fig.10 (b). The crack in the metabiolite grain being cut propagates quickly along its cleavage plane if its cleavage plane is about 45° or small, causing the fracture chip to curl over. The metabiolite is much softer than other mineral grains in granite. If a metabiolite grain is adjacent to a quartz or feldspar grain being cut, 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 the crack right to the metabiolite cleavage plane will propagate cross metabiolite grain while some cleavage microcracks occur. This pattern of crack development is caused by the instability due to kinking in the metabiolite grain [15, 6]. If the cutting process of granite is assisted by low-pressure water jet, the action of wedging, washing will change the fracture mechanism noticeably [18-20]. When water is jetted into the cutting zone, it flushes away the rock fractured by the action of the cutting tool, causing the crushed zone difficult to form. Further more, the granite strength decreases because of the pressure wedge into the cutting zone, which leads to microcracks generating and developing easily. 0.2mm 0.2mm (a) (b) Fig.10 The propagation of crack in a metabiolite grain ( Fine size granite, ap=0.1mm, γo= -5°, αo=6°, cutting direction“ ←”) Models of Rock Cutting Mechanism. The diabase cutting process is different with that of granite due to their different material properties and mineral structure. The crushed zone and fracture chip in diabase cutting have more regular shape than those in granite cutting process. The cutting process of diabase can be described by means of the model in Fig.11 (a). The crushed zone with wedge shape, acting as cutting tool, transfers the cutting force and causes fracture chips. The crushed zone and fracture chip in diabase cutting have more regular shape than those in granite cutting process. The cutting process of diabase can be described by means of the model in Fig.11 (a). The crushed zone with wedge shape, acting as cutting tool, transfers the cutting force and causes fracture chips Intergranular crack Chipping Cleavage crack Fracture chips Cutting tool Cutting tool Main crack Main crack Crushed zone Crushed zone Granite 299 300 301 302 303 304 305 306 307 308 The cutting process of granites includes the following stages (shown in Fig. 11(b)) (1) The crushed zone forms under formed by the press of the cutting tool; (2) The cracks and microcracks form and develop by the action of tensile stress. The cracks reach the free surface, leading to formation of fracture chip, granular chip and powder chip. (3) The formation and propagation of cracks and microcracks are affected greatly by the depth of cut, the material properties, such as grain size, mineral composition, cleavage plane, and grain boundary, etc. 309 Conclusions 310 (1) The diabase cutting process is different with that of granite due to their different material (a)Diabase Fig.11 (b) Granite Models of rock cutting mechanism 311 312 313 314 315 316 317 318 319 320 properties and mineral structure. (2) The crushed zone, cracks and chipping form under the action of tensile stress both in the cutting processes of diabase and granite. The main crack in diabase may develop under the mixed action of tensile stress and stress. (3) The crushed zone and fracture chip when cutting diabase have more regular shape than those when cutting granite. (4) The mineral properties have more remarkably influences on the propagation of microcracks and cracks in granite than in diabase. 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