This paper presents a comprehensive model of the dynamic tool force / motion error relationship for diamond turning. A key to a successful control of diamond turning process to achieve the theoretical finish lies in understanding the relationship that governs the generation of dynamic tool motion errors due to the variation in tool force. However, this relationship is neither well established nor simple, and is dependent upon material properties, various machining parameters, and the wear condition of the tool. In Part I, a model for this relationship is developed based upon the variations in the geometry of the tool and workpiece interaction resulting from their dynamic motion errors. The model is obtained as a first order variation from a static relationship, and consists of stiffness and damping terms. The total stiffness terms are characterized by variations in the chip geometry due to dynamic motion errors along the thrust direction. The thrust component of this model is then verified experimentally using the measurements of motion errors while simultaneously measuring the dynamic tool forces.

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