A dynamic surface topography model for the prediction of nano-surface generation in ultra-precision machining

Materials induced vibration has its origin in the variation of micro-cutting forces caused by the changing crystallographic orientation of the material being cut. It is a kind of self-excited vibration which is inherent in a cutting system for crystalline materials. The captioned vibration results in a local variation of surface roughness of a diamond turned surface. In this paper, a dynamic surface topography model is proposed to predict the materials induced vibration and its effect on the surface generation in ultra-precision machining. The model takes into account the effect of machining parameters, the tool geometry, the relative tool–work motion as well as the crystallographic orientation of the materials being cut. A series of cutting experiments was performed to verify the performance of the model and good correlation has been found between the experimental and simulation results.