Performance-based predictive models and optimization methods for turning operations and applications: Part 2 - Assessment of chip forms/chip breakability

This paper presents recent developments in chip control research and provides major applications in turning operations involving the use of complex grooved tool inserts. On the basis of the basic chip morphology presented by Nakayama (1984), four major parameters contributing to complex 3-D chip curl are identified: chip back-flow, chip up-curl, chip side-flow, and chip side-curl. A summary of past research in each of these four categories is presented as well as a description of an attempt to combine these parameters into one readily measured variable. An analysis of cyclic chip formation is then presented with experimental evidence from high-speed filming of the chip curling and breaking processes. The most commonly known "chip chart" technique is then described. The paper concludes with details of an attempt to develop a computer-aided process planning system incorporating a predictive capability for chip breakability in turning operations.