Experimental research on the critical conditions and critical equation of chip splitting when turning a C45E4 disc workpiece symmetrically with a high-speed steel double-edged turning tool

Chip splitting is a natural chip separation phenomenon that can significantly reduce cutting energy consumption. To reveal its occurrence mechanisms, a method for obtaining its critical conditions through cutting experiments and establishing its critical equation is proposed in this paper. Based on previous research results regarding the relationship between chip removal interference and chip splitting, the control variables that affect chip splitting are identified by analyzing a geometric model of the cutting process. A total of 366 experiments on turning a C45E4 disc workpiece with a high-speed steel double-edged turning tool based on the dichotomy method were conducted and 51 experimental data on chip splitting critical conditions were obtained. According to these experimental data, a critical equation expressed by a finite-degree polynomial with a cutting thickness equal to the other control variables was fitted. By analyzing the critical surface, it was determined that chip splitting followed a law in which the smaller the cutting thickness and the larger the absolute value of the negative rake angle, edge angle, and edge inclination of the tool, the more likely chip splitting was to occur. Through a verification experiment, it was determined that the derived critical equation could accurately predict the occurrence of 95.24% of chip splitting. It was also determined that the occurrence of chip splitting led to a cliff-like drop in the specific total cutting force with a maximum drop of 51.23%. This research lays a foundation for the rational utilization of chip splitting in tool structure parameter design and cutting parameter energy saving optimization.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00378-7