An Investigation on the Theories of Orthogonal Machining

Abstract

We have shown a general view of the extant theories on the orthogonal machining in steady state, especially paying attention to the existing limits of the complete solution. It is convenient for estimating these limits to investigate the existing range of the cutting resistance P/Tk related to the shear angle φ applying Hill's theorem to the rigid regions. We investigated the generalized case of the Lee and Shaffer's solution with built-up edge and it is proved that the chip should be rigid contrary to Lee and Shaffer. We attempted some experiments using lead specimens and the obtained relations between φ and λ-α coincided with the theory, but the values of P/Tk were scattered and slightly larger than the theoretical range as a whole. It seemed that φ was affected by the initial condition.