溝付き工具を用いた切りくず案内切削の機構

Abstract

The mechanics of “chip-guiding cutting” with grooved tools are investigated in the present study. The chip-guiding cutting has been proposed by the authors to realize continuous chip disposal. It has been clarified in the previous study that chips can be guided successfully into desired directions with the grooved round-nose tools, but the mechanics of the new cutting process with the guide grooves has not been clarified. Fundamental chip-guiding cutting experiments are carried out with grooved straight-edge tools in this study. An analytical model for the chip-guiding cutting process is developed. Effects of the chip-guiding on the process parameters such as cutting forces are investigated accurately by the proposed model and validated by cutting experiment. Both experimental and analytical results unveil that chip flow direction can be controlled by chip-guiding forces generated by the side-walls of the groove structure engraved on the rake face. It is shown that as the chip flow direction can be altered to the various guide directions from the original one, and the proposed model predicts that as the guiding force increases, shear angle decreases and thus resultant cutting force is increased only slightly. Therefore, when the guide direction is not dramatically different from the original chip flow direction, the resultant cutting force is not increased significantly, which make the process favorable. These results support the fact that proposed model captures the critical cutting mechanics accurately.