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The cutting mechanism under conditions of progressive flank wear was analyzed theoretically. General expressions for depth of cut and stock removal rate were derived, taking variation of tool forces into consideration.Ferritie nodular cast iron was machined with carbide and ceramic cutting tools, and variation of tool forces associated with progress of flank wear was investigated. It was found that tool forces increased with an increase in flank wear in almost linear relationship, and that the rate of increase in feed cutting force was greater than that in principal cutting force.

Flank Wear Progress and Variation of Tool Forces