Abstract
Chip flow control is an important issue for automated machining. Using the cutting power equilibrium equation of Usui et al. (ASME J Eng Ind 100:222–228, 1978) and Usui and Hirota (ASME J Eng Ind 100:229–235, 1978), a new chip flow angle prediction model is derived for helical vee grooves turning with sharp corner tools and is expressed as the transformed cutting power equilibrium equation in which the value of the principal cutting force F is experimentally measured. In this study, RATIO is defined as the ratio of the main to the minor cutting edge length engaged in cutting and is a set variable on the basis of the constant equivalent cutting area. The chip flow angle corresponding to different values of RATIO predicted by the current model shows good correlation with the experimental measurement, and FEM simulation results for various cutting conditions. An investigation of the effect of RATIO on the chip flow angle is made under various cutting conditions, and it is demonstrated that RATIO has a significant influence on the chip flow angle.
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