Burr and shape distortion in micro-grooving of non-ferrous metals using a diamond tool

Burr and shape distortion are two main problems in micro-grooving. Tn this study, a simplified model is proposed based on large thrust force due to th e tool edge radius. Experiments are conducted with a single crystal diamond tool on a 3-axis shaper-like machine varying the depth of cuts, and groove angles on brass, aluminum and OFHC. Experiments have shown that the thrust force becomes a dominant variable in burr generation compared to the princ ipal force when the depth of cut is less than 2 mum. And fewer burrs develo p on more brittle materials. Shape distortion is significant only when the groove angle is small and the depth of cut is larger than 30 mum.