Influence of material swelling on surface roughness in diamond turning of single crystals

Abstract

The effect of material swelling on the surface roughness in ultraprecision diamond turning has been investigated. Experimental results from the power spectrum analysis indicate that the pro®le of the tool marks is distorted by the effect of swelling of the materials being cut. A good correlation exists between the surface roughness and the amount of swelling that has occurred in the machined layer. Radically different surface roughness pro®les were obtained when machining aluminium and copper single crystals with the same cutting plane and tool shape. The difference in the machining behaviour could not be accounted for by elastic recovery alone but could be explained by considering the plastic deformation induced in the machined layer.MST/4449

A study of materials swelling and recovery in single-point diamond turning of ductile materials

“…This implies that the plastic deformation is not only along the feed marks but also in between the feed marks [10]. Although it has been reported that side swelling would lead to slightly wider tool marks in some cases, the effect is relatively insignificant when compared with deep swelling [11]. Deep swelling is due to the thrust cutting force along the main cutting edge of the tool as shown in Fig.…”

Effect of plastic side flow on surface roughness in micro-turning process

“…The effect of material swelling in ultra-precision diamond turning has been investigated [10] and a good correlation between the surface roughness and the amount of elastic recovery has been shown. Influences of vibration [11][12][13] and crystallographic orientation [14] on surface roughness in diamond turning have also been investigated.…”

A review of machine-tool vibration and its influence upon surface generation in ultra-precision machining

“…In UPM, surface roughness is influenced by many factors, including cutting conditions [3], material pile-up [4], material swelling and recovery [5,6], crystal orientation [7,8], material properties [9,10], relative vibration between tool and workpiece [11,12], tool vibration [13], and spindle vibration [14]. A plethora of research has been conducted on the machinability of non-ferrous materials, such as copper and aluminum, and on chip formation with shear angle in UPM [15][16][17][18][19].…”