Cutting force prediction for ultra-precision diamond turning by considering the effect of tool edge radius

• Cutting force model for ultra precision diamond turning is developed.
• The model takes into account the effect of tool edge radius.
• The cutting force is calculated based on a piecewise cutting force function.
• The minimum chip thickness is estimated based on an experiment.
• Friction induced vibration due to elastic recovery is investigated.

Many studies have been conducted to develop algorithms for cutting force prediction in a variety of machining process. However, few studies have developed the cutting force prediction algorithm by considering the effect of tool edge radius in ultra-precision diamond turning, including fast tool servo/slow tool servo assisted diamond turning. This paper presents a cutting force prediction algorithm for the ultra-precision diamond turning, which is able to take into account the effect of tool edge radius. The developed algorithm is general for predicting cutting force in most cylindrical diamond turning processes such as fast tool servo/slow tool servo assisted diamond turning. Experiments are conducted to validate the cutting force prediction algorithm. The experimental results verify the assumed relationship between the chip formation and the minimum chip thickness, where the work material is entirely removed when the uncut chip thickness is larger than a certain value. The estimated value of minimum chip thickness is obtained. The measured cutting force shows good agreement with the simulated value. In addition, the friction induced vibration due to elastic recovery occurs when a worn diamond cutting tool is adopted in the experiment.