Improving nanocutting surface quality by force-controlled rolling

Abstract

Force-controlled rolling method which is a combination of rolling tool, force sensor and fast tool servo is proposed to realize real-time control of rolling force in surface modification process. Especially when the surface is complex, the rolling force can be changed dynamically based on the surface profile and the rolling path. Therefore, the machinability of soft material, such as lead (Pb), are easy to be modified by force-controlled rolling. After the soft and sticky workpiece, lead, is modified, the surface of it becomes hard enough to suppress the scratch of the chips, the formation of built-up edge, and the side flow of the workpiece material at the subsequent nanocutting process. Nanocutting of Pb mirrors validates the effectiveness of the force-controlled rolling method. Besides that, side flow region under the action of the tool edge and its evolution after the formation of build-up edge is investigated.