During metal cutting processes, the cutting tool is subjected to high cutting forces and high temperatures that lead to excessive wear. The application of rotary tools provides an alternative to improve wear resistance and prolong tool life. Self-propelled rotary tool machining is described as a process whereby a disk shape insert cuts a workpiece and the insert is also rotated by the chip flowing on the tool rake face. A better understanding of the rotary tool machining process will benefit the selection of tool geometry and cutting parameters, and contribute to continuous productivity improvements in the manufacturing industries.;Verification of the force model was performed through a set of rotary tool cutting experiments. A series of machining tests were performed on a tube end of steel. Cutting forces were measured under different process parameters. The insert self propelled motion was monitored and measured under different conditions and the measured insert speed used to predict the chip flow direction.;A comparison between the predicted and measured chip flow direction showed a good agreement. In the second stage of the analysis the chip flow direction was used to predict the cutting forces based on the analysis of orthogonal cutting. The predicted forces were comparable to the measured ones under a wide range of feed and cutting speed.;In this work, the mechanics of cutting with self-propelled tools was analyzed. The chip flow directions were also investigated under different cutting parameters. The analysis of the chip flow is used in modeling the forces generated during the chip formation process. The analysis was carried out based on the equivalent transformation from the basic orthogonal cutting process. A force model for self-propelled rotary tools was developed and used to investigate the effect of feed and cutting speed on the generated forces.
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