Model for cutting force prediction in high precision single-point diamond turning of optical silicon

Abstract

This paper presents a mathematical model predicated on a finite series convergent scheme and derivative functions of multi-variants obtained from a cutting force constitutive equation for onward prediction of the maximum cutting force at the tip of a single-point diamond tool (SPDT). The three variants amidst other parameters in the model include the tool length, width and strain effect. The model basically operates under two components, namely the dynamic and predictive components. Prior to the predictive analysis, cutting experiments were carried out using an ultra-high precision machine to diamond-turn units of single-crystal silicon workpiece. Results from nine experimental trials are presented. Other supporting devices deployed for signal monitoring and conditioning include the use of a Kistler force sensor, an analog-digital (AD) sensor for data acquisition and an amplifier unit for signals. The cutting parameters adopted for the experimental process includes depth of cut, feed rate and cutting speed. The simulation interval for the investigation of the cutting force was fixed at intervals of 1 mm from the point of sensor insert to the tip of the tool. The dynamical response of the proposed algorithm to each experimental trial, as seen in the displayed results, shows a trend commensurate to the geometry of the diamond-cutting tool and stiffness of the machined material.