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In order to observe orthogonal cutting phenomenon of gray iron at a low speed (v=40mmi min) accurately, the side view of the metal cutting process was continuously photographed through a microscope by a motor-driven 35mm camera with a pair of cynchronized flash light source. Cutting resistance and surface roughness were also measured so that these terms were studied with reference to the type of the chip formation. From the test data, it was found that three types of the chip formation : namely the crack , shear and tear types, occurred alternately in machining of gray iron . The shear type occurred more frequently than other types. Surface roughness produced by the crack and tear type chic formation was greater than that by the shear type. A decreased tool rake angle resulted in the increased surface roughness, and a more dominance of the sh2ar type chip formation to other types.

Dynamical Observation of Cutting Mechanism in Machining of Gray Iron (Part 1)