Modeling and experimental verification of chip flow deviation in oblique cutting

The reasons for chip deviation from the orthogonal direction in machining are (i) restricted cutting effect, (ii) nonzero inclination angle, and (iii) tool-nose radius. The present article has incorporated the concept of effective inclination angle in the models for predicting chip flow direction in oblique cutting. Model 1 takes into account the role of the effective principal cutting edge angle (as point function) and the concept of effective inclination angle has been incorporated in the model. Model 2 addresses the same roles but determined as path functions. Models 1 and 2 do not address the variation in the chip load along the width of cut. This has been addressed in Model 3 along with effective inclination angle. The models have been validated against the experimental data while turning two different medium carbon steels with uncoated carbide inserts over a wide domain of depth of cut, feed, cutting velocity, nose radius, rake angle, inclination angle and principal cutting edge angle. The major contribution of this work is the introduction of effective inclination angle along the effective cutting edge.