Efficient Chip Control at Reduced Power Consumption: An Experimental Analysis

This paper presents some results of a large study on chip breaking conducted by the authors using tool inserts with grooved chip formers. The paper covers an analysis of the effectiveness of chip breaking and the corresponding power consumption analysis for a range of tool contact lengths, groove sizes, groove shapes and cutting conditions (particularly, the undeformed chip thickness). Major findings of this work indicate that efficient chip breaking is achievable at reduced power consumption. This outcome is expected to make a contribution towards designing optimum chip breakers, which would also take other factors such as tool-life and surface finish into account.