Study on a new turning method to simulate orthogonal cutting and to verify an edge breakout model

In order to verify an edge breakout predicting model in orthogonal cutting, which was proposed by the author’s previous work, orthogonal machining experiments must be conducted. A CNC lathe was utilized to carry out simulated orthogonal cuttings. The workpiece, made of aluminum alloy Al 6061-T6, is a cylindrical bar with square threads and axial/radial grooves. Threading and grooving inserts with a flat cutting edge were chosen as the cutting tools. The experimental data were used to verify the previously developed edge breakout model. The tests showed excellent agreement with the model predictions.