FUNDAMENTAL-STUDIES OF DRIVEN AND SELF-PROPELLED ROTARY TOOL CUTTING PROCESSES .1. THEORETICAL INVESTIGATION

The various types of rotary tool cutting operations and their performa nce advantage over conventional machining operations are reviewed toge ther with the simplified or fundamental operations used to study the c utting mechanics of these novel material removal operations. The funda mental driven and self-propelled rotary tool cutting operations have b een simulated as wedge tool cutting processes and their relationships to the kinematically and perfectly equivalent ''classical'' orthogonal and oblique cutting processes explored. Based on the modified thin sh ear zone cutting models the simulated driven orthogonal and oblique ro tary tool cutting processes have been analysed and represented as perf ectly equivalent classical oblique cutting processes accounting for al l the cutting forces and energy, together with a chip transportation p rocess, owing to the tool lateral motion along its cutting edge, which involves no additional energy. By contrast, the self-propelled obliqu e rotary tool cutting process has been modelled as a perfectly equival ent classical orthogonal cutting process together with chip transporta tion. The proposed models will be experimentally verified in the next part of this investigation.