Micro-Machining of Copper and Aluminum Crystals

The process of chip formation in copper and aluminum single crystals has been examined with a scanning electron microscope. The morphology of the shear planes clearly illustrates that the actual deformation zone (layer or shear front) is an extremely thin and well-defined band of slip planes wherein the predominant deformation takes place. The appearance of the top or upper surface of the chip corresponds to the micro mechanisms operating during the process of machining.