Effect of tool and workpiece anisotropy on microcutting processes

The effect of crystallographic orientation of diamond tools and workpiece m aterials on microcutting processes was investigated in order to improve the machined surface quality. Experimental and analytical results show that th e influence of tool and workpiece orientations on the diamond cutting proce ss cannot be neglected especially when higher machining accuracy is require d. The coefficient of friction between diamonds and workpiece materials was found to be sensitive to the crystallographic orientation of diamond cryst als. 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 force s and surface roughness in diamond cutting of single-crystal copper and alu minium has been studied. The origin of the cutting force variation with cry stallographic orientation of the material being cut has been analysed on th e basis of a microplasticity model.