ABSTRACT
The study of the mechanics of chip formation is of great industrial importance since the chip formation parameters enable us to compute the cutting forces and other related machining variables. This chapter establishes the mechanics of chip formation in machining by first making a distinction between orthogonal cutting and oblique machining. The chip formation in machining is discussed and quantitatively analyzed with the aid of mathematical models. Importance of machining parameters (e.g., chip-thickness ratio, rake angle, shear plane angle, shear plane area, shear force, shear stress, etc.) has been inter-related through mathematical models. The effects of rake angle and shear plane angle on machinability are discussed with the aid of diagrams. Merchant’s equation is explained and applied to justify the use of lubricants for better machinability in industrial practice. The four types of chips (segmented or discontinuous chips, continuous chips, continuous chips with built-up edge, and serrated chips) have been identified and explained. This chapter contains 8 diagrams and 12 calculations/worked examples.
