A hybrid predictive model and validation for chip flow in contour finish turning operations with coated grooved tools

Unlike straight turning, the effective cutting conditions and tool geometry in contour turning operations are continuously changing with changing workpiece profile. This causes a wide variation in chip flow during the operation. Unfavorable chip flow can cause scratch/damage the machined surface, and lead to tool failure due to chip build up at the cutting edge. This paper presents a new methodology to predict the chip side-flow angle for complex grooved tool inserts in contour turning operations as well as experimental validation. Computer program has been developed to apply the predictive model to any contour workpiece profile and the capability of the predictive program is also presented in this paper.