An analysis of strain in chip breaking using slip-line field theory with adhesion friction at chip/tool interface

A slip-line field model for orthogonal cutting with step-type chip breaker assuming adhesion friction at chip/tool interface is developed using Kudo's basic slip-line field. An alternative method is suggested for estimation of breaking strain in the chip. The model proposed predicts that with decrease in distance of chip breaker from the cutting edge of the tool, the breaking strain and shear strain in the secondary deformation zone increase while the total plastic strain decreases. The breaking of the chip is found to be solely dependent on the breaking strain, and not on 'material damage' or the specific cutting energy. The chip radius of curvature, cutting ratio, range of position of chip breaker for effective chip breaking are computed. The calculated results are found to be in general agreement with experimental measurements. © 2005 Elsevier B.V. All rights reserved.