Three-dimensional cutting force analysis based on the lower boundary of the shear zone .1. Single edge oblique cutting

Traditional models of cutting based on Merchant's shear plane idealization are incapable of predicting any of the cutting force components without a priori knowledge of chip-tool friction. However, Rubenstein's work on orthogonal cutting has shown that this limitation can be avoided by utilizing the stress distributions on the lower boundary of the shear zone. The present work aims to extend this approach to oblique cutting with single and two edged tools. This paper focuses on single edge oblique cutting whereas Part 2 analyses two edge cutting. It is assumed that the progressive deformation of the work material into chip material occurs within the effective plane. The resulting stress distributions on the lower boundary are integrated to yield expressions for estimating cutting forces from given tool and chip geometries. This provides a mechanism for predicting the power and lateral components of the cutting force in single edge oblique cutting. The predictions are verified against new and previously published experimental data.