Case study of surface micro-waves in ultra-precision raster fly cutting

In ultra-precision raster fly cutting (UPRFC), very high frequency microwaves in the range of 3.42 MHz–6.36 MHz are found on the machined surface. This study conducted a series of theoretical and experimental investigations to discover the origin of these microwaves and how they might be suppressed. Research results show that: (i) microwaves on the machined surface are caused by the material sliding during the chip formation in UPRFC; (ii) owing to the inconsistent thickness of chips along their length direction, the microwaves accumulate at the surface-exit in each feed length; and (iii) chip thickness and tool wear change the length and distribution of the microwaves. This research provides a deep insight into the formation of microwaves along with suggestion on how to suppress them.