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 profile 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 profiles 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.
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