The roughness of the ultramicrotomed block face of AA2024 in Al area was 1.2 nm.
Surface texture associated with chattering was evident in grains with 45° diamond knife.
A 76° rake angle minimises the stress on the block face.
Using the oscillating knife with a cutting speed of 0.04 mms−1 minimised the surface texture.
A variety of material applications were presented.