Computing approach of uncut chip thickness in orthogonal turn-milling with inserted cutters

The computing of uncut chip thickness is the basis for further studying the cutting mechanism as well as simulating the cutting process. The research about orthogonal turn-milling operation with inserted cutters was focused on. By simplifying the trajectory of cutting edge,the uniform formulation to calculate uncut chip thickness for cutters with different shapes was derived and then compared with the numerical method through several examples. Upon the presented formulation of uncut chip thickness,the cutting force in orthogonal turn-milling operation was predicted and a validation experiment was carried out on a turn-milling machine tool. Both the comparison examples and the result of cutting force prediction show that the presented approach can provide a solution for the calculation of uncut chip thickness with good accuracy and high computation efficiency. Due to the uniform expression,the proposed approach is suitable for the development of general simulation software for orthogonal turn-milling process and thus has potential value in engineering practice.