Abstract
In this study, the relationships between chip thickness and the energies consumed in the cutting process, using a simplified cutting model in which the effect of surface plastic flow on chip thickness was considered, were analyzed under the supposition that the ratio of energy consumed by the effect of surface plastic flow remaining on the machined surface to total cutting energy is equivalent to the ratio of additional chip thickness resulting from the effect of surface plastic flow to measured chip thickness. C2801 brass, A1100 aluminum, and SUS304 stainless steel were cut orthogonally at a low cutting speed and the effect of surface plastic flow on the cutting mechanism was compared among the three materials. The following results were obtained. Total cutting energy was composed of four energies : shear energy without the effect of surface plastic flow, friction energy without the effect of surface plastic flow, energy consumed in surface plastic flow, and additional friction energy resulting from the effect of surface plastic flow. With the use of the “chip constant” which is specific to a material and is negligibly affected by cutting conditions, the energies consumed in the cutting with plastic flow can be expressed as a function of shear strain. In the cases of C2801, A1100, and SUS304, the ratios of energy consumed by the effect of surface plastic flow remaining on the machined surface to total cutting energy were approximately 10%, 13%, and 17%, respectively.
