<p>The removal process of brittle materials constitutes a complex system characterized by multivariate inputs and outputs. The removal mechanism functions as a critical linkage, establishing correlations between input variables (material properties) and output responses (surface morphology characteristics). The complexity arises from the intricate interplay of multiple influencing factors: workpiece material anisotropy, tool geometry and dynamic tool-workpiece contact conditions. Fundamentally, the material removal mechanism is governed by the intrinsic properties of the workpiece material. At the macroscopic scale, the resultant surface morphology predominantly exhibits fracture-induced damage features attributable to crack propagation phenomena. Microscopically, the removal process induces complex subsurface alterations, including the crystallographic defects such as dislocations and slip bands, microstructural transformations evidenced by hardness variations, residual stress fields, and potential elemental redistribution near the machined surface. A systematic investigation of the interrelationships among material properties, surface morphology characteristics, and removal mechanisms is crucial for elucidating the fundamental material removal behavior in brittle solids. This study aims to elucidate the governing role of removal mechanisms in brittle material processing, and establish a comprehensive classification framework for applicable removal mechanisms corresponding to distinct material characteristics and processing conditions. The removal mechanisms of brittle materials can be classified into three categories: (1) crack propagation removal mechanism, primarily governed by fracture dynamics; (2) material-property-alteration mechanism, involving phase or chemical transformations; (3) micro-scale material-removal mechanism, characterized by atomic-level displacement phenomena. Subsequently, this review examines the historical evolution and contemporary understanding of these mechanisms, with particular emphasis on their theoretical foundations and practical implications. Furthermore, the distinctive features of each mechanism are comprehensively analysed through comparative evaluation. The discussion concludes by identifying current research limitations in brittle material removal theory and proposing potential directions for future investigations. This study provides fundamental insights into material removal behavior, contributing significantly to the mechanistic understanding of removal processes.</p>

Overview of the removal mechanism of brittle materials: multidimensional analysis

期刊论文
发表日期：

2026年1月8日

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Ma Lianjie,
Cheng Siyu

摘要

The removal process of brittle materials constitutes a complex system characterized by multivariate inputs and outputs. The removal mechanism functions as a critical linkage, establishing correlations between input variables (material properties) and output responses (surface morphology characteristics). The complexity arises from the intricate interplay of multiple influencing factors: workpiece material anisotropy, tool geometry and dynamic tool-workpiece contact conditions. Fundamentally, the material removal mechanism is governed by the intrinsic properties of the workpiece material. At the macroscopic scale, the resultant surface morphology predominantly exhibits fracture-induced damage features attributable to crack propagation phenomena. Microscopically, the removal process induces complex subsurface alterations, including the crystallographic defects such as dislocations and slip bands, microstructural transformations evidenced by hardness variations, residual stress fields, and potential elemental redistribution near the machined surface. A systematic investigation of the interrelationships among material properties, surface morphology characteristics, and removal mechanisms is crucial for elucidating the fundamental material removal behavior in brittle solids. This study aims to elucidate the governing role of removal mechanisms in brittle material processing, and establish a comprehensive classification framework for applicable removal mechanisms corresponding to distinct material characteristics and processing conditions. The removal mechanisms of brittle materials can be classified into three categories: (1) crack propagation removal mechanism, primarily governed by fracture dynamics; (2) material-property-alteration mechanism, involving phase or chemical transformations; (3) micro-scale material-removal mechanism, characterized by atomic-level displacement phenomena. Subsequently, this review examines the historical evolution and contemporary understanding of these mechanisms, with particular emphasis on their theoretical foundations and practical implications. Furthermore, the distinctive features of each mechanism are comprehensively analysed through comparative evaluation. The discussion concludes by identifying current research limitations in brittle material removal theory and proposing potential directions for future investigations. This study provides fundamental insights into material removal behavior, contributing significantly to the mechanistic understanding of removal processes.