Chip breaking performance of cutting tools with unusual forms.

This work shows one solution of the problem of predicting the chip breaking performance of a groove-type chip breaking device. The relationships between the dimensions of a simple grooved tool and the range of undeformed chip thickness which gives acceptable chip breaking are reexamined by conducting cutting tests on laboratory prepared tools. These experiments enable the repeatability of data to be assessed. The range of workpiece materials is also extended. A nomogram is devised, using the results of these tests, to predict the range of undeformed chip thickness over which chips are broken satisfactorily from a knowledge of the tool dimensions. The nomogram meets one need specified in a survey of tool users in the Sheffield area which is for a simple, scientific method of fitting a chip breaker to cutting conditions. It is recognised that computers have a part to play in developing the nomogram principle and that the scope of the nomogram could be greatly increased using this medium. In response to another requirement of tool users in industry the project is widened to consider the behaviour of some recently produced commercial tools. The aim of this investigation is to comment on the effect each profile has on the chip breaking performance of the tool. It is necessary to separate and classify features on the tools since the profiles are in some cases very complex and not easy to analyse. Assessment is made of how readily the nomogram can be applied to each of the tool-types considered.