An improved model for oblique cutting and its application to chip-control research

Abstract

The traditional model for oblique cutting has two shortcomings, one being that it involves only one machining case where the tool major cutting edge angle is limited to be 90°, i.e. the undeformed chip thickness is equal to the feed of the tool; whilst the other is that it takes no account of the influence of the tool feed velocity on the resultant cutting velocity. In this present work, an improved model for oblique cutting is developed in which the influences of the two above factors, i.e. the tool major cutting edge angle and the tool feed velocity, on machining processes are considered. The new cutting model can be used to determine precisely some important parameters involved in machining processes, e.g. the effective rake angle of the tool, the effective shear angle and the consumption of cutting power, etc. As a practical example, the model that is established, combined with a theory on the minimum energy consumption, is used to carry out chip-control research. The chip flow direction and the chip flow speed are determined. The theoretically-predicted data is found to agree reasonably well with the experimental results under the given experimental conditions.