3-DIMENSIONAL CUTTING FORCE ANALYSIS BASED ON THE LOWER BOUNDARY OF THE SHEAR ZONE .1. SINGLE-EDGE OBLIQUE CUTTING

Traditional models of cutting based on Merchant's shear plane idealiza tion are incapable of predicting any of the cutting force components w ithout a priori knowledge of chip-tool friction. However, Rubenstein's work on orthogonal cutting has shown that this limitation can be avoi ded by utilizing the stress distributions on the lower boundary of the shear zone. The present work aims to extend this approach to oblique cutting with single and two edged tools. This paper focuses on single edge oblique cutting whereas Part 2 analyses two edge cutting. It is a ssumed that the progressive deformation of the work material into chip material occurs within the effective plane. The resulting stress dist ributions on the lower boundary are integrated to yield expressions fo r estimating cutting forces from given tool and chip geometries. This provides a mechanism for predicting the power and lateral components o f the cutting force in single edge oblique cutting. The predictions ar e verified against new and previously published experimental data.