Purpose: A multi-scale model is proposed to explain the effect of material induced vibration and the quantitative relation between cutting force and the surface quality from dislocations, grain orientations, cutting tools, machine tools used in the simulation of the nano-3D surface topology in single-point diamond turning. Design/methodology/approach: The model-based simulation system composes of several model elements which include a microplasticity model, a dynamic model and an enhanced surface topography model. Findings: This research is the first attempt in which the microplasticity theory, theory of system dynamics and machining theory are integrated to address the materials problems encountered in ultra-precision machining. Indeed, this is a new attempt to link up the microplasticity theory to macro-mechanisms in metal cutting. The successful development of the model-based system allows the prediction of the magnitude and the effect of periodic fluctuation of micro-cutting force and its effect on the nano-surface generation in ultra-precision diamond turning of crystalline materials. It also helps to explain quantitatively the additional roughness caused by the variation of the crystallographic properties of the workpiece, and leads us to a better understanding of the further improvement of the performance of ultra-precision machines. Research limitations/implications: The multi-scale model brings together knowledge from various disciplines to link up physical phenomenon occurring at different length scales to explain successfully the surface generation in single-point diamond turning of crystalline materials. Originality/value: This model offers a new direction of research in ultra-precision machining.
