A MODEL FOR NON-FREE-CUTTING

An the real machining operations are of non-free-cutting, which is cha racterized by the interference of the chip ejections from different se gments of the cutting edges. The rapid advancing of modern cutting tec hnology makes the non-free-cutting processes even more complex. Powerf ul theories are badly needed for explaining, understanding and predict ing the intricate phenomena arising in non-free-cutting operations. In the paper, a ''Hypothesis of Minimum Energy'' is suggested based on t he results of experiments. In the light of the hypothesis, the natural chip ejection vector of a free-oblique-cutting tool and the interfere nce and compromise among chip ejections upon non-free-cutting were mat hematically modeled. The model is capable of predicting the ejection v elocity and direction of the common chip as an integrity, the chip def ormation and the cutting force of a non-free-cutting process. Good agr eements between predictions and experiments were identified. The crite ria for realizing free cutting and for chip splitting are also present ed and discussed in this paper.