Force and spatial profile analysis of surface generation of single point diamond turning

In ultra-precision machining, the vibration sensors were conventionally mounted underneath the tool holder. In this paper, investigation has been made to study how representative the vibration signals captured could be by corresponding them with the arithmetic average value of surface profile in ultra-precision facing process. To correlate the surface profile data with the cutting process, a spatial profile retracing algorithm was developed to retrace the changes of profile along the cutting path from a measured 3D surface profile. By statically comparing the spatial and vibration signals, it was found that the tool-work vibration, which was along the cutting direction, was identified to be the most significant factor affecting surface generation. Even though the normal of the surface profile was parallel to the thrust force direction and was perpendicular to the cutting direction, the surface profile variation was found to bear more similarities to the tool-work vibration than that of the thrust force vibration.