Modeling of Undetached Chip Shape on Finishing Processing Toolpath

During milling cutting of spherical surfaces, the added material is removed in the form of chips. The controlled conditions that determine the size and shape of the undetached chip are defined by the technological parameters (feed per tooth and depth of cut) or by the geometrical parameters (thickness and width of the chip). The shape of the undetached chip is influenced by the geometry of the tool, by the milling mode (cut-up milling, cutdown milling), by the feed direction. There are mathematical models, mostly plane, for defining the shape of the undetached chip. These mathematical models become extremely complicated when considering machining of a spherical or a non-analytical surface. This paper presents a parametric model built in a CAD environment that determines the shape of the undetached chip when machining a spherical zone with a torodial end mill.