Cutting force model of orbital single-point micromachining tool

This paper presents an analytical, ductile cutting force model of a novel micromachining tool that is based on micro-orbital motion of a single-point tool tip. The single-point tool tip used in this study is a single crystal diamond stylus that consists of a cone section of 50° and a spherical tip with radius less than 1 μm. The tool is actuated by a piezo tube that generates a high frequency micro-orbital motion of a single-point tool tip in a circular trajectory. Unlike conventional micromilling, where the cutting occurs at the edges of the tool flutes, a single-point tool may utilize any point on the circumference surface of the tool tip. Also, due to its extreme negative rake angle at small depths of cut, the technique can machine brittle materials such as silicon in the ductile regime. Experiments were performed on an aluminum alloy (AL2024) to obtain the specific cutting force and the coefficient of friction in order to calculate the cutting forces in all 3 axes and to verify the model.