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Abstract
The purpose of this research was to clarify the behaviour of ultra-precision diamond machining with an infeed range of approximately 1 to 10 nm. The machining behaviour and the sharpness of the diamond tool edge were monitored by cutting noise measurements, the chips were observed with a scanning electron microscope (SEM) and the machined surface observed with an interference microscope. As a result, it was concluded that a mirror surface is generated at a machined section depth which is smaller than the cutting edge radius of the tool. Hence, it is very important to pay close attention to the chip producing behaviour. The shear angle was not maintained throughout the chip, as two different shear angles, 14° and 17°, were observed. These values were dependent by the value of the undeformed chip thickness compared with the cutting edge radius. Even during micro-infeed ultra-precision diamond machining, the surface temperature of the chips during machining was assumed to be rather high, exceeding the melting temperature (approximately 660°C) for aluminium alloys.
Published Version
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