A new method for predicting the chip flow angle of inserts with different cutting conditions was studied in non-free oblique machining process. The effects of the major cutting edge, minor cutting edge, corner radius and cutting parameters (depth of cut and feed rate) on the chip flow direction were studied by calculating the components of the thrust cutting force for the major and minor cutting edges based on the hypothesis that the chip flow direction is also the thrust force direction. This method was verified by comparing the calculated and experimental results with the single-point and nose-radiused cutting edge for different cutting conditions. The prediction results under different cutting parameters show good agreement with experimental data.
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