An Analysis of Strain in Chip Breaking Using Slipline Field Theory with Adhesion Friction at Chip/Tool Interface

Abstract

Despite rapid growth in the applications of metal machining in manufacturing, a comprehensive analysis of the problem of chip control has always been a di±cult task. This is because of the complex mechanism of the chip formation process and a lack of knowledge of the factors that in°uence chip form/chip breakability under a given set of input machining conditions such as work material properties, tool geometry, chip breakers and cutting conditions. Consequently, the solution to the problem has been approached empirically with a limited degree of success. In the present investigation, an attempt has been made to examine chip breaking by a step-type chip breaker using the rigid-plastic slip-line ¯eld theory. Orthogonal machining is assumed and the deformation mode is analysed using the solutions pro- posed earlier by Kudo and Dewhurst. The rake face friction is represented by the adhesion friction law suggested by Maekawa et al. The ¯elds are constructed and analysed by the m...