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TECHNICAL PAPERS

A Microplasticity Analysis of Micro-Cutting Force Variation in Ultra-Precision Diamond Turning

[+] Author and Article Information
W. B. Lee, C. F. Cheung, S. To

Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong

J. Manuf. Sci. Eng 124(2), 170-177 (Apr 29, 2002) (8 pages) doi:10.1115/1.1454108 History: Received December 01, 1999; Revised August 01, 2001; Online April 29, 2002
Copyright © 2002 by ASME
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References

Drescher,  J. D., and Dow,  T. A., 1990, “Tool Force Model Development for Diamond Turning,” Precision Engineering, 12, No. 1, pp. 29–35.
Lo-A-Foe, T. C., G., Dautzenberg, J. H., and van der Wolf, A. C. H., 1988, “Cutting Forces and Their Influences Upon the Surface Integrity in Single-Point Diamond Turning,” Ultra-precision Manufacturing Engineering, Proceedings of the International Congress for Ultraprecision Technology, Springer-Verlag, pp. 110–125.
Kim,  J. D., and Kim,  D. S., 1995, “Theoretical Analysis of Micro-cutting Characteristics in Ultra-precision Machining,” J. Mater. Process. Technol., 49, pp. 387–398.
Arcona,  C., and Dow,  Th. A., 1998, “An Empirical Tool Force Model for Precision Machining,” ASME J. Manuf. Sci. Eng., 120, pp. 700–707.
König, W., and Spenrath, N., 1991, “The Influence of the Crystallographic Structure of the Substrate Material on Surface Quality and Cutting Forces in Micromachining,” Proc. 6th Int. Precision Engng. Seminar, Braunscheweig, Germany, pp. 141.
Sato,  M., Kato,  K., and Tuchiya,  K., 1978, “Effect of Material and Anisotropy Upon the Cutting Mechanism,” Trans. JIM., 9, pp. 530–536.
Black,  J. T., 1972, “Shear Front-lamella Structures in Large Strain Plastic Deformation Processes,” ASME J. Eng. Ind., 94, No. 2, pp. 307.
Lee,  W. B., and Zhou,  M., 1993, “A Theoretical Analysis of the Effect of Crystallographic Orientation on Chip Formation in Micro-machining,” Int. J. Mach. Tools Manufact., 33, No. 3, pp. 439–447.
Lee,  W. B., Cheung,  C. F., and To,  S., 2001, “Characteristics of Microcutting Force Variation in Ultraprecision Diamond Turning,” Materials and Manufacturing Processes, 16, No. 2, pp. 177–193.
Bishop,  J. F. W., and Hill,  R., 1951, “A Theory of the Plastic Distortion of a Polycrystalline Aggregate Under Combined Stresses,” Phil. Mag., 42, pp. 414.
Reid, C. N., 1973, Deformation Geometry for Material Scientists, Pergamon Press.
Lee,  W. B., and Chan,  K. C., 1991, “A Criterion for the Formation of Shear Band Angles in F.C.C. Metals,” Acta Metallurgica et Materialia, 39, No. 3, pp. 411–417.
Merchant,  M. E., 1945, “Mechanics of the Metal Cutting Process. I: Orthogonal Cutting and A Type 2 Chip,” J. App. Phys., 16, pp. 267–275.
Moon, F. C., 1998, Dynamics and Chaos in Manufacturing Processes, Wiley, New York.
Shamoto,  E., and Moriwaki,  T., 1994, “Study of Elliptical Vibration Cutting,” CIRP Ann., 43, No. 1, pp. 35–38.

Figures

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The co-ordinate systems for the cutting geometry
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A schematic diagram of the signal flow in cutting force measurement
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Predicted variation of shear angle with crystal orientations in diamond turning aluminum single crystals on (a) (001) plane and (b) (111) plane
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Predicted variation of the cutting force with crystal orientations in diamond turning aluminum single crystals on (a) (001) plane and (b) (111) plane
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Power spectral plot for the cutting force in air cutting
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(a) Predicted and (b) measured power spectral plots of the cutting force for diamond turning aluminum single crystal with (001) as the cutting plane
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(a) Predicted and (b) measured power spectral plots of the cutting force for diamond turning aluminum single crystal with (111) as the cutting plane
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Effect of depth of cut on the power spectral densities (PSD) of the cutting force in diamond turning aluminum single crystal with (001) cutting plane: (a) is the predicted and (b) is the measured
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Effect of depth of cut on the power spectral densities (PSD) of the cutting force in diamond turning aluminum single crystal with (111) cutting plane: (a) is the predicted and (b) is the measured

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