Chip Formation Mechanism in Single Crystal Cutting of β-Brass

Summary The subject of this study is to analyse chip formation mechanism of single crystals. The mechanism during diamond cutting of 3-brass is investigated in association with the crystallographic orientation of the cutting geometry system. The main experimental technique used is the direct scanning electron microscope observation of in-situ chip formation. It is found that the pattern of chip formation of the single crystal is largely affected ty the cutting direction with respect to the crystallographic orientation. Continuous chip due to lamellar slip structure formation in the shear zone is mostly observed. However, the pattern changes to the discontinuous type caused by micro-cracking for the particular orientation. The shear angle changes from about 15 decrees up to 60 degrees, depending on the variation of the crystallographic orientation. The shear angle measured is compared with the value predicted from the crystal plasticity analysis. The effect of the orientation on the cutting force characteristics and the surface integrity are also discussed.