Fundamental studies of driven and self-propelled rotary tool cutting processes—I. Theoretical investigation

TLDR: In this paper, the fundamental driven and self-propelled rotary tool cutting operations have been simulated as wedge tool cutting processes and their relationships to the kinematically and perfectly equivalent classical orthogonal and oblique cutting processes explored.

Abstract: The various types of rotary tool cutting operations and their performance advantage over conventional machining operations are reviewed together with the simplified or fundamental operations used to study the cutting mechanics of these novel material removal operations. The fundamental driven and self-propelled rotary tool cutting operations have been simulated as wedge tool cutting processes and their relationships to the kinematically and perfectly equivalent “classical” orthogonal and oblique cutting processes explored. Based on the modified thin shear zone cutting models the simulated driven orthogonal and oblique rotary tool cutting processes have been analysed and represented as perfectly equivalent classical oblique cutting processes accounting for all the cutting forces and energy, together with a chip transportation process, owing to the tool lateral motion along its cutting edge, which involves no additional energy. By contrast, the self-propelled oblique rotary tool cutting process has been modelled as a perfectly equivalent classical orthogonal cutting process together with chip transportation. The proposed models will be experimentally verified in the next part of this investigation.