Shear and friction processes in intermittent cutting

In intermittent cutting processes, characterized by the use of rotating tools, the undeformed chip thickness varies periodically according to the phase change of tool. Although many studies have already concentrated on intermittent cutting processes, there has been no previous analysis of the shear and friction processes. In the current study, an up-end milling process is transformed into an equivalent oblique cutting process. The varying undeformed chip thicknesses and cutting forces in the up-end milling process are thus replaced with the equivalent average ones. As a result, the shear process in shear plane and the chip-tool friction process of intermittent cutting are analyzed using the equivalent oblique cutting model. The validity of the proposed analysis was verified based on two sets of cutting tests i.e. up-end milling and equivalent oblique cutting tests.