Microwave formation mechanisms in surface generation of ultra-precision machining

Abstract

In ultra-precision machining (UPM), surface microwaves have been commonly produced on the machined surface along with lamellar chips. However, the intrinsic characteristics of surface microwave formation in UPM have not been understood well. Therefore, a theoretical and experimental investigation has been conducted into microwave formation mechanisms of surface generation in UPM. The results revealed that in UPM, the lamellar chip formation caused cyclic cutting forces to induce material recovery and tool vibration, namely chip formation induced material recovery and tool vibration. Accordingly, it caused surface microwaves on the machined surface. Further, a theoretical model has been developed qualitatively to represent the relationship between chip formation induced material recovery and tool vibration and surface microwaves. It was well identified by the machined and simulated surface topographies in UPM.