Modeling and experimental investigation of surface generation in diamond micro chiseling

Abstract The investigation of diamond micro-chiseling (DMC) has been studied as a machining process for generating specific surface microstructures. The current research mainly focuses on the processing performance of DMC in different applications without exploring the DMC surface generation process from the principle. This article studies the DMC surface generation process under different processing parameters through both theoretical and experimental parts. In the theoretical part, an accurate surface generation model is created that considers the effects of geometrical relationships, material removal mechanisms, minimum uncut chip thickness, and dynamics. The geometric model of the diamond chiseling tool is described, the trajectory between the tool and workpiece is built, and the minimum uncut chip is considered and established. Regarding dynamic factors, a spring-mass damping vibration system of DMC is established, and a finite element model is built to analyze the cutting force. In the experimental part, DMC surface generation experiments are conducted to explore the material removal mechanism and compare surface topography. Results show that our simulation model can estimate DMC topography with an error of less than 0.5 µm. Simultaneously, the optimal DMC strategy is obtained through experiments.