Abstract
The conventional model predicts that the surface roughness decreases with feed and fits well with the measured results, even in the micro turning process. But it is observed that surface roughness increases with feed decreases when the feed is in the range of micro scale. Based on the analysis of peak-to-valley formation process, a quadratic prediction model, which divides the height of peak-tovalley into two parts: one part is piled in front of the rake face while the other is piled on the flank face and is more accurate, is established considering the effect of tool geometry, cutting parameters and pile-up of work piece. The prediction model is calibrated and verified via two groups of micro turning experiments. Results show that size effect of specific cutting energy increases the surface roughness at small feeds. The difference between the theoretical and measured results at small feeds is mainly induced by the pileup of work piece material around the rear face. The best surface roughness can be obtained when the feed per revolution equals 0.1 time of the cutting edge radius.
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