Micro-machining of glassy polymers: effect of tool wear and process parameters on the cutting-induced shape defects

This paper aims to investigate the contribution of tool wear and process parameters to the shape defects induced by the micro-machining of glassy polymers such as polycarbonate. An experimental approach is proposed in this study using an instrumented orthogonal cutting configuration. Diamond inserts have been considered as a cutting tool and have been subjected to different levels of accelerated wear. The worn tools were first characterized to identify the wear mechanisms that occurred on the active cutting zone and were then used to perform orthogonal cutting experiments on polycarbonate. Micro-cutting depth values (3–20 µm) were considered to respect the micro-machining configuration. Chip morphology, cutting forces, and machined surfaces’ topography have been acquired to analyze and assess the effectively removed material depth regarding the theoretical cutting depth for each worn tool. Results show that the increase of the cutting edge radius is the main wear mechanism that occurred in the diamond inserts. This tool wear evolution was found to be the most influential factor on the induced shape defect by increasing the elastic deformation of polycarbonate rather than its shear when using micro-cutting depths, which induces a spring-back of polycarbonate after cutting.