Abstract: Every year, a huge number of chips are produced, while the recycling of waste meets difficulties and the high cost issue. The present recycling process always takes the formed chips into process, which needs complex work-flow, and leads to a low level of economic efficiency. As a novel chip recycling technology, forming extrusion cutting (FEC) can directly turn the chips into grooved strips during the chip forming stage, which has little effect on the normal cutting process, and the grooved strips are featured with industrial value as fins. This process is energy and cost efficient. However, there are few studies on the deformation process of FEC. It deals with the deformation process of FEC, as well as the effect concerning forming performance from different chip compression ratios λ, different rake angles of the cutting tool α and different groove structures. The result shows that among the ranges from 0.7 to 1.5, the forming conservation rate decreases with the increase of λ, while the forming conservation rate failed to show trends with the variation of α from 10°to 30°. At the condition of λ=0.7 and α=10°, the forming conservation rate of each structure exceeds 80%, showing that FEC could be effective and stable in producing grooved strips. Furthermore, the surface substructure provides fins produced by FEC with a prospect in the heat transfer industry, thus FEC shows great practical value and development potential.

Key words: chips recycling, forming extrusion cutting, grooved strips, surface substructure