Smooth surface is important to the performance of many biological and microoptic instruments. In our cutting process research,
we analyzed theoretically and experimentally the formation of
amorphous polymers and found a way to its smooth cutting. Amorphous polymers chip formation is sometimes similar to metal chip formation. Our cutting process research revealed three types of unusual amorphous polymer chip formation. We established a model for each unusual type of amorphous chip formation, i.e., Figs.1,2 and 3. We then derived eq.(6) as the cutting moment formula for all three types of unusual amorphous polymer chip formation. Finally we derived eq.(7) as the relationship governing smooth cutting. In eq.(7), cutting moment is related to cutting parameters σ r, r, a c, a w . Among the four, a c, the cutting depth, is the most important. The first author had the good fortune of using the precision SMM(scanning mechanical microscope) of ENSMM(Ecole Nationale Superieur des Microtechniques et Mècaniques), located in Besancon, FrancheComtè, France,to study the topography of
machined surface of amorphous polymers material, shown in Figs.5 and 6. The preedgecrackpropagating chip formation process (Fig.1) leads to the smoothest surface (Fig.5) of amorphous polymer material.