Predictive modelling for enhanced scratching of brittle ceramics with magneto-plasticity

The micro-cutting of brittle ceramics starts with elastic-plastic deformation followed by severe brittle fracture, which significantly restricts the machinability and application of these materials. Magnetic field-enhanced plasticity (i.e., magneto-plasticity) has shown a positive potential to augment the ductile-brittle transition and machinability but the material removal mechanism of brittle ceramics with magneto-plasticity and its dependence on strain rate remains unclear. In this study, a deformation energy-based model was developed to bring light to the deformation mechanisms affecting the ductile-brittle transition under magneto-plasticity and the corresponding dependency on strain rate. MD simulations assisted the analytical modeling by deriving the orientation-dependent dislocation movement and stress distribution that contribute to single-crystal anisotropy in the surface formation and ductile-brittle transitions during scratching. The proposed model accurately predicted the improvement in ductile-brittle transition under various magnetic field intensities and orientations as confirmed in the experimental magnetic field-enhanced micro-scratching tests on single-crystal calcium fluoride (CaF2). Scratched surface morphologies, acoustic emission (AE) signals, and critical loading conditions demonstrated the improvements in ductile-brittle transition with magneto-plasticity. Additionally, the progression of lateral slip trace and tangential surface pile-up under various magnetic field conditions confirm the direct influence of magneto-plasticity on dislocation mobility and the change in surface formation mechanism of brittle ceramics. This study not only deepens the understanding of the manifestation of magneto-plasticity during the deformation of brittle ceramics, but also opens new avenues for the integration of magnetic field-assisted technology in manufacturing processes.