Micromechanics of Machining and Wear in Hard and Brittle Materials.

Hard and brittle solids with covalent/ionic bonding are used in a wide range of modern-day manufacturing technologies. Optimization of a shaping process can shorten manufacturing time and cost of component production, and at the same time extend component longevity. The same process may contribute to wear and fatigue degradation in service. Educated development of advanced finishing protocols for this class of solids requires a comprehensive understanding of damage mechanisms at small-scale contacts from a materials science perspective. In this article the fundamentals of brittle-ductile transitions in indentation stress fields are surveyed, with distinctions between axial and sliding loading and blunt and sharp contacts. Attendant deformation and removal mechanisms in microcontact processes are analyzed and discussed in the context of brittle and ductile machining and severe and mild wear. The central role of material microstructure in material removal modes is demonstrated.