The goal of this research is to develop a detailed, quantitative, experimentally verified model of the chip breaking process using high pressure, two-phase coolant. The chip control system injects this high pressure, two-phase stream of cutting fluid into the chip formation zone. The fluid stream breaks the forming chip into short segments. While this process is relatively simple in practice, the details of it are not known. The research is aimed at developing a fundamental understanding of this new chip control scheme by postulating an appropriate model. The analytical model will relate the chip breaking process to machining and chip control system conditions. The end result of this research will be an experimentally verified model which can be used to predict broken chip length given work material properties, cutting conditions, and coolant and coolant flow characteristics. Further, the experimental work will include measurements of machined surface finish and cutting tool wear. These results will be useful in themselves and will also indicate the extent of the effects of the chip control system on the chip formation process.
