This paper presents a new study of chip formation in orthogonal cutting. The work has shown that the known model of chip formation based on the analytical description of the shear process alone has already reached its maximum development and still matches practical results only occasionally. Therefore, the further progress in the cutting theory may be achieved only by introducing some other mechanisms to account for the phenomena in the deformation zone. Naturally, this new mode of deformation should be considered together with shearing to explain the chip formation. This paper aims to introduce the bending moment as a cause of chip formation. The presence and the significance of the bending moment in the chip formation process have been demonstrated both theoretically and experimentally.

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