Effects of the friction coefficient on the minimum cutting thickness in micro cutting

In the ultra precision diamond cutting process, the rake angle of the tool is likely to become negative because the edge radius of tool is considerably large compared to the sub-micrometer depth of cut. The round edge of the tool might sometimes cause plowing results in a poor surface, or burnishing which results in a shiny surface depending on the depth of cut. This study deals with the relationship between the friction of a tool-workpiece and the minimum cutting thickness in micro cutting. Proposed is an ultra precision cutting model in which the tool edge radius and the friction coefficient are the principal factors determining the minimum cutting thickness with a continuous Chip. According to the model, a smaller edge radius and a higher friction coefficient make the cutting depth thinner. The experimental results verify the proposed model and provide various supporting evidence. (C) 2004 Elsevier Ltd. All rights reserved.