Aspects of Surface Generation in Orthogonal Ultraprecision Machining

Summary The depth of the plastically deformed layer at the workpiece surface which resulted in the orthogonal ultraprecision machining of Cu over the range of uncut chip thicknesses of 0.01-10 μm was investigated. Two tools with the same nominal geometry but with differing edge geometries were used to machine both Te-Cu and fine grain Cu. Tool edge geometries were characterized by atomic force microscopy, taking into account the AFM cantilever tip radius. Magnitudes of the measured depths appear to be consistent with values reported in the literature and those arrived at by simple analyses.