A numerical investigation on the effect of tool geometry in single point diamond turning of silicon

A simulation study using mesh-free Lagrangian Smooth Particle Hydrodynamics (SPH) formulation in conjunction with machining experiments was carried out to study the effect of different rake angles of diamond tool on the machining mechanism of silicon. A 3D SPH model is developed to estimate the cutting forces and stresses for different tool geometry. An experimental study is performed to study the effect of different rake angles on chip formation mechanism. The simulation and experimental results show that tool geometry significantly influence machining quality and transition into different machining modes. The study also reveals that SPH is a valuable and easily implemented approach in studying brittle machining and its results are adequately in good agreement with experimental results.