Study on the forming mechanism and evolutionary pattern of stagnant region in mechanical scratching

In this paper, a combination of theoretical modeling, finite element simulation, and experimental methods is employed to investigate the forming mechanism and evolutionary pattern of the stagnant region during mechanical scratching with a diamond wedge tool. The study is structured as follows: Firstly, a theoretical calculation model for the geometric parameters of the stagnant region on the formed groove surface is established based on the contact friction partition mechanism and slip-line field theory. The model indicates that the geometric parameters l_B-sg, l_V-sg, and ∆l_sg of the stagnant region are determined by the length of the stagnant region l_p-sg in the plastic flow plane and the transformation parameters. Secondly, the formation process of the stagnant region in mechanical scratching is investigated using an orthogonal cutting simulation model with a negative rake angle tool. The results reveal that the stagnant region is a plastic deformation region formed due to the geometrical characteristics of the negative front surface of the scratching tool and its excessive extrusion, which leads to the formation of adhesive friction within the material. Thirdly, the characteristics of the stagnant region are determined through scratching experiments. Compared to the material in the plastic flow region, the material within the stagnant region exhibits finer and denser microstructures, reduced surface hardening peaks and hardened layer depths, and significantly improved surface roughness. Finally, the evolutionary pattern of the stagnant region under the influence of scratching processing parameters is examined based on the theoretical calculation model of the geometric parameters and the scratching experiment. The findings indicate that as the wedge angle of the scratching tool decreases, the relief angle increases, the absolute value of the rotation angle around the Y-axis decreases, the scratching speed decreases, and the material's plastic adherence improves, the P_I/k value decreases, the l_p-sg value increases, and consequently, the geometric parameters l_B-sg, l_V-sg, and ∆l_sg of the stagnant region on the formed groove surface also increase. The deviation analysis of the geometric parameters of the stagnant region reveals a consistent trend between the theoretical and experimental values of l_V-sg and ∆l_sg, with maximum deviations of 15 μm and 4.13%, respectively. This study provides theoretical and experimental evidence for the establishment of the theoretical model of the stagnant region in mechanical scratching, the analysis of its forming mechanism, and the control of the stagnant region geometric parameters on the formed groove surface.