Using molecular dynamics (MD) computer simulation, an attempt is made to analyze and understand the chip removal process in micro metal cutting under sub-nanometric uncut chip thickness. Microcutting experiments on copper workpiece are also carried out under the uncut chip thickness down to 1 nm. Comparison shows a fairly reasonable correlation between the chip morphologies and the size effect in the cutting force and specific energy obtained from both MD simulation and microcutting experiments. The results suggest that MD simulation can be a useful tool for the analysis of chip and surface generation process in microcutting. The chip formation process is well understood as the successive generation of dislocations on tool-work interface and their passing through the shear zone to the free surface.
