1. As the first attempt of analytical research on cutting mechanics, the deformations of continuous chips were observed in the process of orthogonal machining for copper, stainless steel and lead. The following facts observed are considered to have an important meaning for cutting mechanics.
(i) On the outer surface of a chip (a free surface of material before machining) there are many rough crinkles which are parallel to the direction of width of cutting edge, and each crinkle looks like the shape of both edges of a cold-rolled sheet metal.
(ii) On the inner surface of a chip (a surface contact with a rake surface of tool) there are flow lines inclined to the direction of a frictional force between tool and chip. The field of those inclined flow lines is within 30% of thickness of a chip.
(iii) A plastic deformation takes place in the material before a shear plane, and accompanies a swelling-up portion on its free surface.
2. Many investigators who have researched cutting mechanics, assume a geometrical. model in which a zone of a deformation is regarded as a single shear plane and containing a simple shear deformation only. In this report this geometrical model is called a "simple model of chip formation."
On the other hand, from the above mentioned facts, the author assumes a new geometrical model in which the deformation takes place in a plastic zone and accompanies a swelling-up portion on the free surface of material. This new geometrical model contains deformations by simple shear and pure shear, and is called a "complex model of chip formation."
3. In the complex model of chip formation the author assumes a simple shear deformation which equals to the energy of frictional deformation of a chip at the tool-chip contact.
This assumption makes it easy to understand the energy of frictional deformation of chip.
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