Abstract
The cutting mechanism in ultraprecision-machining of aluminum single crystals having various orientations using a trial ultraprecision machine was investigated. The (111) plane cutting requires the lowest cutting force and provides the best finished surface roughness among those for (001), (110) and (111) planes. The cutting in the direction of [011] on (111) plane gives the best finished surface roughness .The cutting forces and shear angles were affected by the crystal orientation when the depth of cut was 3 and 4μm. The crystal orientation dependency was not observed at a cutting depth of 1 and 2μm. This is reasonably explained by an affected layer, and this characteristic phenomena is shown in the micro cutting. The cutting force varies when shear strain is less than 3 according to the result on the relation between shear stress and shear strain. The finished surface roughness is affected by the cutting direction, suggesting that the control of the workpiece orientation is effective for improving the working accuracy. Width of lamella on the free surface of chips is affected by the cutting direction and depth of cut.
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