Modeling chip formation with grooved tools

Abstract A slip-line field model for orthogonal cutting with a tool containing a groove-like feature on its rake face is proposed. Primary contact at the tool-chip interface is taken to be plastic. Based on experimental observations, it is assumed that the chip flows into the groove, and is forced to curl by Coulomb friction contact with the groove back wall. Solutions obtained for different groove geometries, groove positions relative to the cutting edge, rake angles and tool-chip interface friction using the matrix operator method are presented and discussed. The calculated results are in general agreement with experimental observations. It is found that the model can be formulated so that it can be used to predict the cutting geometry for obstruction-type chip breakers as well.

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