A class of slipline field solutions for metal machining with sticking–slipping zone including elastic contact

In the present investigation, slipline field solutions for orthogonal machining with elastic contact are presented when the plastically stressed region in the chip/tool contact length consists of both slipping and sticking zones. The interface friction in the elastic as well as plastic contact zone is assumed to obey Coulomb’s law. Solutions are obtained both for parabolic and exponential normal stress distribution in the elastic contact region. A constant ratio of elastic to plastic contact length is assumed. Results are presented for variation of cutting forces, cutting ratio, chip-curl radius, contact length, the sticking length and sticking ratio with variation in rake angle and interface friction. The variation of normal and shear stresses at the chip/tool interface with variation in coefficient of friction as well as rake angles is predicted. Results from the theoretical analysis are compared with experimental values reported in the literature.