Analysis of the Swelling Effect in Single-Point Diamond Turning

The swelling effect is an important factor to affect surface generation in SPDT. Face cutting experiments are conducted for copper, aluminum alloy and electroless nickel phosphorus to analyze the swelling effect including the relationship between it and cutting parameters as well as effect of material property. How the material swelling affects surface roughness is also studied in this paper. The results indicate that the swelling effect is influenced by spindle speed and material property more remarkably when compared to feed rate and depth of cut. In addition, a softer and more ductile material will lead to a stronger material recovery, a lower swelling proportion, a lower tool mark height and a smoother machined surface. The result reveals that the swelling effect must be considered when predicting surface roughness in SPDT.