Abstract
The present paper deals with experiment and analysis of hole machining of plastic with a sharp knife edge tool. The cutting experiment is conducted at various cutting depths and tool postures, and cutting force components and cut surface profiles are measured in order to investigate mechanics of the cutting process. A simple analytical model is also constructed to better understand the process, where a constant contact pressure and a constant friction coefficient are assumed between the tool and the workpiece. It is confirmed that the experimental and analytical results are in a good agreement, and it shows that the knife-cutting of the plastic (HDPE) can be understood as the simple process where the above assumptions in the analysis are roughly satisfied. From this finding, some suggestions are derived to improve the practical hole machining process for production of automobile fuel tanks made of the plastic.
