Abstract
The technology required for ultra-precision machining of non-ferrous metals is relatively well established, owing to significant improvements in the performance of the hardware used. However, no satisfactory analytical model has been developed for very small cutting depths of this process, demonstrating that the physics of the ultra-precision machining process are not well understood. This paper presents the development of an ultra-precision cutting model based on fluid mechanics that considers not only cutting tool geometry, including the cutting edge radius, but also the effect of elastic rebound at the flank face. This is the first time that a fluid dynamic model has been used to predict the effect of a cutting edge, its size effect, and the cutting forces during ultra-precision cutting. This model can also be used to provide estimates of the chip curling radius and tool-chip contact length.
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