Prediction of tool-chip contact length using a new slip-line solution for orthogonal cutting

Tool–chip contact length is an important parameter in machining. Several ways had been proposed in different works to find its value, which gave discordant results for the same set of cutting conditions. In this paper, a new slip-line solution for orthogonal cutting by a tool with unrestricted rake face is suggested. Based on the proposed solution, a new formula for tool–chip contact length has been obtained. Comparative analysis of different methods to predict tool–chip contact length has been done and experimental verification conducted. The suggested formula has shown to correspond well with experimental data and predicts tool–chip contact length better than other known solutions.  2003 Elsevier Ltd. All rights reserved.