Experimental Verification of a Catastrophe Theory Model of Metal Cutting Chip Formation

Abstract

The problem of predicting changes in the chip formation process in metal cutting was considered. An analytical model which predicts the shear angle as the cutting tool approaches the end of the workpiece was developed. The model was of the orthogonal cutting geometry with shear along a plane and the shear angle predicted from a minimum shear energy postulate. The model predicted two shear angles near the end of cutting and these were compared with measured shear angles for cutting different work materials with varying rake angle tools.