Prediction of chip flow direction during machining with self-propelled rotary tools

This paper presents a model for chip flow prediction during tube-end machining process using self-propelled rotary tools. The analysis performed is based on the transformation of the relative kinematic relationships in rotary cutting to that of the conventional cutting with large nose radius. Both relative and absolute chip flow angles are investigated. Tests were performed to measure the absolute chip flow angle, insert self propelled motion, and the deformed chip thickness during machining with self-propelled rotary tool under different cutting conditions. The predicted values of the absolute chip flow angle were in good agreement with that measured experimentally.