Study of chip-breaking mechanisms in orthogonal cutting. Technical report, April 1, 1990--June 30, 1991

This report summarizes the activities of the research project entitled {open_quotes}Study of Chip Breaking Mechanisms in Orthogonal Cutting{close_quotes}. The research effort took place from April 1990 to June 1991. The overall objective of the project was to develop a systematic procedure for gaining a more fundamental understanding of chip breaking mechanics. Central to this objective is a computer model that can simulate chip formation in orthogonal cutting. This model has been under development for the past seven years at NCSU. The model is based on an Eulerian formulation of the finite element technique. The model simulates the cutting process for various tool geometries over a wide range of cutting conditions. The model can be used to predict chip geometry, cutting forces, plastic strains, strain rates, and temperatures in the workpiece and chip, as well as temperatures in the tool itself. Of particular significance is that specific tool geometries can be simulated. Therefore, the model can be used to systematically evaluate the strains, strain rates, temperature, and geometry of the chip as a function of a specific chip-breaker tool design. These results can provide the crucial information necessary to formulate a fundamental understanding of the chip breaking mechanism over a wide range of operating conditions and workpiece materials