A geometric analysis of semi-spiral chip morphology in orthogonal machining

Continuous, unbroken chips used to be a significant manufacturing problem, creating a hazardous situation for the operator and endangering the machine tool. This problem, however, is now largely solved. At this point, further work is needed to optimize well-broken chips. Once chip initial curl and s piral characteristics can be predicted, they can be optimized as part of th e overall cutting process design. This may decrease the need for cutting fl uids to flush the chips from the cutting region, thereby facilitating a mor e environmentally conscious process design. Analytic and experimental work is performed to investigate chip spiral morphology and develop a predictive orthogonal chip model. The analytic semi-spiral chip prediction model of C ook et al., (1) is extended to the constricted envelope case. Numerically d eveloped chips are created to investigate the effects of generalized obstru ction geometry. The process inputs that have statistically significant effe cts on chip morphology are determined to confirm the model.