Experimental investigation of dynamic chip formation in orthogonal cutting

Orthogonal planing experiments are conducted with high-speed camera recordings and simultaneous cutting force measurements in order to analyze chip formation during machine tool vibrations. By means of carefully designed periodic forcing of the cutting tool, non-stationary cutting experiments are performed including wave generation, wave removal and wave-on-wave cutting, which are then compared to stationary cutting tests. The experiments are performed to address how the cutting force is affected by the chip thickness variation, the surface waviness and the fluctuation of the cutting direction. The results are used to assess some theoretical models that involve shear angle variation and chip segmentation.