Systems analysis of semi-discontinuous chip formation and assessment of chip deformation

Film motion analysis technique(5000 frames/sec) was adopted to study the velocity variation of segmental chips in machining titanium alloy, and the process of chip segmentation in machining was considered as a system with cutting speed as input and chip velocity along the tool face as output. Dynamic cutting ratio was derived from experimental observations for measuring cutting efficiency, and for convenience in engineering evaluation, a quasi-static or equivalent cutting ration was derived from the dynamic cutting ratio. Besides, a dynamic shear angle was derived to replace the customary shear angle. The calculated values were in good agreement with experimental results.