Effect of tool and workpiece anisotropy on microcutting processes

Abstract

The effect of crystallographic orientation of diamond tools and workpiece materials on microcutting processes was investigated in order to improve the machined surface quality. Experimental and analytical results show that the influence of tool and workpiece orientations on the diamond cutting process cannot be neglected especially when higher machining accuracy is required. The coefficient of friction between diamonds and workpiece materials was found to be sensitive to the crystallographic orientation of diamond crystals. The anisotropy in the friction coefficient of diamonds is responsible for the variation in shear angle with tool crystal orientation. The effect of the crystallographic orientation of workpiece materials on cutting forces and surface roughness in diamond cutting of single-crystal copper and aluminium has been studied. The origin of the cutting force variation with crystallographic orientation of the material being cut has been analysed on the basis of a microplasticity model.