Characterization of nanosurface generation in single-point diamond turning

This paper describes a parametric analysis of nanosurface generation in single-point diamond turning (SPDT). The properties of the surface roughness profiles were extracted and analysed using the power spectrum analysis method. A series of face cutting experiments was undertaken on an aluminium alloy (6061) under various cutting conditions. The results indicate that the power spectrum of a surface roughness profile is basically composed of several periodical components that can be correlated to different process parameters and mechanisms of surface generation. Moreover, it is found that the tool feed, tool geometry, spindle error motions and relative vibration between the tool and the workpiece are not the only dominant components contributing to the surface generation in SPDT. Materials swelling and tool interference are other important factors. Based on these findings, relationships are proposed to explain the influence of tool interference on the variation of the spectral components and process parameters. The implications of these findings on the optimization of the surface quality in SPDT are also discussed