Abstract
Constrained cutting is a novel cutting process which employs an additional constraining tool in combination of the cutting tool to enable the control of chip-forming deformation in the cutting process. In this study, a linear cutting setup equipped with force sensors was developed and used to conduct constrained cutting experiments on highly ductile OFHC copper at three controlled chip thickness ratios. The chip thickness ratio was controlled by altering the constraining tool position in the setup. The setup allows the cutting tool forces and constraining tool forces to be measured separately in the constrained cutting process. Free cutting experiment was also conducted for comparison. The results show that the total cutting force (or equivalently the cutting energy consumption) is up to 50% lower in constrained cutting than in free cutting. Both the cutting and thrust forces on the cutting tool are reduced by constrained cutting compared to free cutting. The cutting force on the constraining tool is negligibly small while the thrust force on the constraining tool is only moderate. These results indicate the energy consumption by the constraining action is negligibly small while its effect on the cutting energy reduction is substantial. The study confirms the great potential of constrained cutting as an efficient material removal process.
