On the mechanism of dislocation-dominated chip formation in cutting-based single atomic layer removal of monocrystalline copper

For mechanical cutting, when cutting depth is decreased to the atomic scale, minimum chip thickness could be down to a single atomic layer. The material removal is conducted in a new dislocation-dominated chip formation mechanism. It is different from the extrusion-dominated nano-cutting and concentrated shearing-dominated chip formation in micromachining. Serials of molecular dynamics simulations indicate that there are three deformation zones generated within the contact zone between the cutting tool and workpiece materials, including a dislocation slip zone, a chip formation zone and an elastic deformation zone. Under their cooperation, the final material removal could be achieved with a single atomic layer precision. The processed surfaces with a single atomic layer precision can be achieved through this new chip formation mechanism.