Modeling the Chip-Work Contact Force for Chip Breaking in Orthogonal Machining With a Flat-Faced Tool

[+] Author and Article Information
B. K. Ganapathy, I. S. Jawahir

Center for Robotics and Manufacturing Systems, Department of Mechanical Engineering, University of Kentucky, Lexington, KY 40506

J. Manuf. Sci. Eng 120(1), 49-56 (Feb 01, 1998) (8 pages) doi:10.1115/1.2830110 History: Received March 01, 1995; Revised July 01, 1996; Online January 17, 2008


The present tendency towards increased automation of metal cutting operations has resulted in a need to develop a model for the chip breaking process. Conventional cutting force models do not have any provision for the study of chip breaking since they assume a continuous mode of chip formation, where the contact action of the free-end of the chip is ignored in all analyses. The new cutting force model proposed in this work incorporates the contact force developed due to the free-end of the chip touching the workpiece, and is applicable to the study of two-dimensional chip breaking in orthogonal machining. Orthogonal cutting tests were performed to obtain two-dimensional chip breaking. The experimentally measured cutting forces show a good correlation with the estimated cutting forces using the model. Results show that the forces acting on the chip vary within a chip breaking cycle and help identify the chip breaking event.

Copyright © 1998 by The American Society of Mechanical Engineers
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