A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and the cutting conditions, namely feed and depth of cut. By defining an equivalent cutting edge based on the chip flow direction it is then shown how cutting forces can be predicted given the work material's flow stress and thermal properties. A comparison between experimental results obtained from bar turning tests and predicted values for a wide range of tool geometries and cutting conditions shows good agreement.
ColwellL. V.Predicting the angle of chip flow for single point cutting tools. Trans. ASME, 1954, 76, 199–204.
2.
OkushimaK.MinatoK.On the behaviour of chip in steel cutting. Bull. Jap. Soc. Mech. Engrs, 1959, 2(5), 58–64.
3.
UsuiE.HirotaA.Analytical prediction of three-dimensional cutting process. Part II: Chip formation and cutting force with conventional single point tool. Trans. ASME, May 1978, 100, 229–235.
4.
UsuiE.HirotaA.MasukoM.Analytical prediction of three-dimensional cutting process. Part I: Basic cutting model and energy approach. Trans. ASME, May 1978, 100, 222–228.
5.
SpaansC.A systematic approach to three-dimensional chip curl, chip breaking and chip control. MR70-241, SME technical paper, 1970.
6.
SpaansC.van GeelP. F. H. J.Break mechanism in cutting with a chip breaker, Ann. CIRP, 1970, 18, 87–92.
7.
van LutterveltC. A.PehelharingA. J.Chip formation in machining operation at small diameter. Ann. CIRP, 1976, 25(1), 71–76.
8.
KluftW.KönigW.van LutterveltC. A.NakayamaK.PekelharingA. J.Present knowledge of chip control. Ann. CIRP, 1979, 28(2), 441–455.
9.
YoungH. T.MathewP.OxleyP. L. B.Allowing for nose radius effects in predicting the chip flow direction, and cutting forces in bar turning. Proc. Instn Mech. Engrs, Part C, 1987, 201(C3), 213–226.
10.
WangJ.MathewP.Predicting the chip flow direction for nose radius tools under oblique machining conditions. University of New South Wales report 1988/IE/2, 1988.
11.
WangJ.MathewP.Prediction of chip flow direction and cutting forces in oblique machining with nose radius tools. University of New South Wales report 1988/IE/5, 1988.
12.
HuR. S.MathewP.OxleyP. L. B.YoungH. T.Allowing for end cutting edge effects in predicting forces in bar turning with oblique machining conditions. Proc. Instn Mech. Engrs, Part C, 1986, 200(C2), 89–99.
13.
LinG. C. LMathewP.OxleyP. L. B.WatsonA. R.Predicting cutting forces for oblique machining conditions. Proc. Instn Mech. Engrs, 1982, 196, 141–148.
14.
MathewP.A theoretical and experimental investigation of the mechanics of machining. PhD thesis, The University of New South Wales, 1983.
15.
OxleyP. L. B.The mechanics of machining: an analytical approach to assessing machinability, 1989 (Ellis Horwood, Chichester).
16.
YoungH. T.MathewP.OxleyP. L. B.Predicting cutting forces in face milling, Int. J. Mach. Tools and Mf. (in press).
