Generation and texture of surfaces in ultraprecision cutting of copper

The texture of diamond-machined optical-quality surfaces on polycrystalline metals is strongly influenced by the anisotropic elastic and plastic properties of the work material. Plunge-cut experiments were carried out on course-grained OFHC copper specimens to examine the correlations between surface topography, process forces, and the orientation of individual grains. Three distinct surface microtopographies were found on individual grains regardless of cutting speed and tool radius. These microtopographies are closely linked with different cutting force levels, which also appear to influence burr formation in the cutting process. The crystallographic orientations of individual grains, which reveal different microtopographies after machining, were determining by X-ray diffraction to correlate the generated surface texture wit the material properties.