Mechanics of cutting model for simulated oblique rotary tool cutting processes

Abstract

Rotary tool cutting processes are described and simulated as ‘orthogonal’ and ‘oblique’. A modified thin shear zone mechanics of cutting model for driven and self-propelled ‘oblique’ rotary cutting tool processes are developed and experimentally verified, qualitatively and quantitatively over a wide range of process variables. The cutting model has been represented as an ‘equivalent’ classical oblique cutting process, accounting for all the cutting energy, together with a chip transportation process due to the lateral tool movement along the cutting edge, which involves no additional energy. From a predictive point of view, the forces, power and absolute chip flow direction in ‘oblique’ rotary tool cutting processes can be obtained from the ‘equilavent’ classical oblique cutting process predictions and the chip transportation analysis in the proposed model. The fundamental and practical implications of the model are discussed.