Chip formation (chip-thickness ratio, shear angle, etc.), cutting force, effect of cutting speed, machinability of materials and tool life were analysed in the previous papers, based upon the machining theory of tool-chip contact area introduced by the author.
Here in this report, surface finish which is one of the most important factors in machinability is discussed based upon the foregoing theory. The surface roughness focused on in this report is that in the direction of the feed marks, because it is more emphasized by the chip formation or the tool-chip contact area and more interesting theoretically than that perpendicular to the feed marks. The fundamental study to abstract the effect of tool-chip contact area upon the surface finish is conducted with tools of which tool-chip contact areas are restricted artificially as well as with normal tools
On the basis of the theory, the effects of cutting speed, feed, tool face roughness and grinding direction of the tool face on the surface finish are experimentally examined. The set of experiments leads to the conclusion that tool-chip contact area per unit area of cut and feed (depth of cut in two-dimensional machining) controle the surface finish in the direction of the feed marks to a large extent ;the former affects the surface finish through the chip formation, and the latter does through the scale of rupture ahead the tool.
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