An Analysis of Conditions and Selection of Modes for Diamond Micro-Milling of Flat Surfaces

This article presents an analysis of high accuracy machining of flat surfaces made of aluminium alloys, potassium dihydrogen phosphate single crystals and silicon single crystals using a single-blade diamond milling cutter. A technique for calculating cutting forces with the cut layer thickness ranging from hundredths to tenths of micrometre that corresponds to the feed from tenths to whole values of micrometre per revolution is developed. An analysis of the variation in the force, cutting temperature and machining accuracy depending on the tool feed and cutting pattern is performed. Comparative data on the cutting forces obtained from literature is presented. The proposed calculation technique is used for investigating operating parameters that provide machining with errors of less than 1 mcm and roughness of 6 nm, including large-size flat surfaces of potassium dihydrogen phosphate single crystals.

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