Abstract
The effects of the nonuniform cutting force and elastic recovery of processed materials in ultra-precision machining are too complex to be treated using traditional cutting theories, and it is necessary to take account of factors such as size effects, the undeformed cutting thickness, the tool blunt radius, and the tool rake angle. Therefore, this paper proposes a new theoretical calculation model for accurately predicting the cutting force in ultra-precision machining, taking account of such factors. The model is first used to analyze the material deformation of the workpiece and the cutting force distribution along the cutting edge of a diamond tool. The size of the strain zone in different cutting deformation zones is then determined by using the distribution of strain work per unit volume and considering the characteristics of the stress distribution in these different deformation zones. Finally, the cutting force during ultra-precision machining is predicted precisely by calculating the material strain energy in different zones. A finite element analysis and experimental data on ultra-precision cutting of copper and aluminum are used to verify the predictions of the theoretical model. The results show that the error in the cutting force between the calculation results and predictions of the model is less than 14%. The effects of the rake face stress distribution of the diamond tool, the close contact zone, and material elastic recovery can be fully taken into account by the theoretical model. Thus, the proposed theoretical calculation method can effectively predict the cutting force in ultra-precision machining.
Highlights
Ultra-precision machining technology is increasingly being used in the production of components with high accuracy and good surface integrity in aerospace, military, optical, mechanical, electronic, and other high-tech applications
Cu and Al are considered as materials to analyze the influence of different cutting parameters on the cutting force of diamond tools in ultra-precision machining
This paper has proposed a theoretical model to calculate the cutting force in such machining and has compared its results with those obtained from finite element simulations and from experiments
Summary
Ultra-precision machining technology is increasingly being used in the production of components with high accuracy and good surface integrity in aerospace, military, optical, mechanical, electronic, and other high-tech applications. Yuan et al. studied the influence of the blunt circle radius of diamond tools on ultraprecision machining and concluded that this parameter determines the size of the minimum undeformed cutting thickness and the integrity of the machined surface. Tian et al. studied size effects on ultra-precision cutting by combining mechanism-based strain gradient (MSG) theory with the traditional Johnson–Cook constitutive model. They established a constitutive model for cutting oxygen-free copper at the mesoscopic scale, which further improved the accuracy of finite element simulation of ultra-precision cutting. There has been insufficient theoretical analysis of ultraprecision machining at the submicrometer and nanometer scales, at which the nonuniformity and crystal boundaries of workpiece materials have a significant influence on the cutting force. The strain energy calculation for each deformation zone is simplified, and the cutting force in ultra-precision machining can be predicted efficiently and precisely
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