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Title: A review of fly cutting applied to surface generation in ultra-precision machining
Authors: Zhang, SJ
To, S 
Zhu, ZW
Zhang, GQ
Keywords: Fly cutting
Surface generation
Ultra-precision fly cutting
Ultra-precision machining
Ultra-precision raster milling
Issue Date: 2016
Publisher: Elsevier
Source: International journal of machine tools and manufacture, 2016, v. 103, p. 13-27 How to cite?
Journal: International journal of machine tools and manufacture 
Abstract: Fly cutting in ultra-precision machining (UPM), termed ultra-precision fly cutting (UPFC), is an intermittent cutting process in which a diamond tool is mounted with a spindle to intermittently cut a workpiece. The process offers the high flexibility necessary for fabricating freeform, micro/nano-structural surfaces, as well as hybrid structural surfaces with sub-micrometric form error and nanometric surface roughness, and its constant cutting velocity provides uniform high surface quality. However, in addition to its low machining efficiency, UPFC's intermittent cutting process results in distinctive surface generation mechanisms, covering intermittent tool-workpiece relative motion, tool geometry imprinted into a machined surface, and surface material separation and deformation. General factors, such as cutting conditions, tool geometry, material factors (material property change, material swelling and recovery, and material separation mechanism), kinematic and dynamic errors, assembling errors, cutting strategies, tool path, and workpiece geometry, are individual to UPFC and universal in UPM. Accordingly, this paper focuses on the current investigation of fly cutting applied into surface generation in UPM. Conclusions are reached and the challenges and opportunities for further studies are discussed.
ISSN: 0890-6955
EISSN: 0890-6955
DOI: 10.1016/j.ijmachtools.2016.01.001
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