Abstract:A mechanical model for the chip side deformation in aluminium alloy cutting is developed according to the plasticity theory.The stresses caused by the chip side deformation and their effects on cutting forces of the rectangular groove cutting are analyzed.It is found that the effect of the chip side deformation on the thrust force F_y is much greater than that on the power force F_z.It is therefore believed that in the rectangular groove cutting a steep rise of the thrust force is the main cause to induce the chatter and hence to produce the poor machined surface.

Key words: metal cutting mechanical model cutting force chip side deformation