An experimental investigation of oblique cutting mechanics

In this work, an experimental analysis of the oblique cutting process for the titanium alloys Ti-
6Al-4V, AISI 4340, and Al 7075 is discussed. We assess crucial process factors such chip flow
angle, shear angle, friction angle, and shear stress. The results are compared with genuine oblique
cutting tests after the data from the orthogonal cutting test results were transformed to oblique
cutting process. Investigated are the effects of hone radius on cutting forces and flank contact
length. It has been found that the shear angle, friction angle, and shear stress in oblique cutting
follow the same pattern as those found in orthogonal cutting tests.
The article results following outcomes:
1. In both orthogonal and oblique cutting, the shear angle increases with the feed rate because
there is less friction on the rake face. This is consistent with the changing trends of the
shear and friction angles. As would be expected, larger shear angles are produced for all
cases of increased rake angles. On the other hand, given the ranges of these parameters
employed in the tests, the shear stress is not significantly impacted by the feed rate, cutting
speed, or oblique angle. These findings support the basic premise of the orthogonal-to-
oblique transformation approach, which uses the friction and shear angles as well as the
shear stress determined from orthogonal cutting in the oblique cutting model.
2. At the oblique angle, edge forces in the feed direction remain almost constant, supporting
a further premise of the transformation process. On the other side, changes in the tangential
edge forces caused by variations in the oblique angle can lead to inaccurate predictions of
the tangential cutting force, particularly at low feed rates. This is explained by how the
third zone's friction conditions vary because of the oblique angle.
3. Cutting force coefficients discovered by orthogonal and oblique cutting experiments reveal
appreciable variations, which become even more pronounced at greater inclination angles.
This demonstrates that correct force estimates in oblique cutting depend on the oblique
model.
4. It has been shown that when the clearance angle increases, the overall cutting forces
decrease. The feed forces are more drastically affected by the clearance angle than are the
tangential forces.
5. In comparison to Stabler's chip flow law, forecasts based on kinematic and force balance
results produce better results for the chip flow angle. Finally, it is demonstrated that
utilizing the projected chip flow angles, the method of oblique transformation applied to
the orthogonal cutting data produces findings that are more accurate than those produced
using the Stabler's rule.