New formulation to characterize chip behaviour during metal cutting process

In this study, the behaviour of a chip during metal cutting processes is analysed using the analogy that the chip behaves mechanically like a beam. This representation simplifies the modelling of the machining process and is used to perform an analysis through basic physical concepts, representing the chip as cyclical formations of small beams, instead of relying on statistical regressions and adjustments that require experimental data. The force components exerted on the chip were determined via Merchant’s force circle. These forces create compression and cause bending, inducing fractures between the work material and the layer to be removed, which shapes and subsequently deforms the chip. Initially, the chip is approximated as a Euler–Bernoulli beam, enabling the quantification of the chip fragment’s length, as well as the forces and deformations involved in its formation. The model results were compared with those from trials reported in the literature, and an excellent approximation was achieved.