Abstract
This paper presents a new analytical model for 2-D machining involving a cyclic chip formation process due to chip breaking. This model includes a chip/work contact force at the free-end of the curled chip which contributes to the development of a bending moment in the chip. Chip breaking occurs when the bending moment and the corresponding chip strain reach maximum. The model provides a predictive capability for forces acting on the chip, bending moment, chip thickness, chip velocity, tool-chip contact length, shear angle, friction angle, etc. for a given set of input conditions such as the work material, cutting conditions, tool rake angle and chip-work friction conditions. Oxley's machining theory was used for predicting the work material shear flow stress at the shear plane. The present work provides a deeper insight into the chip breaking process in machining.
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