Effect of Controlled Modulation on Chip Formation and Interface Tribology in Machining

Based on consideration of mechanics of chip formation, it is shown that the application of a controlled modulation fundamentally changes the nature of the extreme deformation underlying chip formation, and the severe contact conditions at the tool-chip interface. Important consequences are significant reduction in the energy of chip formation, and control of chip shape and size for improved chip management. Implementation of modulation-assisted machining for industrial machining processes is discussed.