Prediction of chip-breaking in machining is an important task for automated manufacturing. According to experiments and previous study, there are chip-breaking limits in machining chip-breaking chart, which determine the chip-breaking range. When inserts with 3-D grooves are used in finish machining, there is an additional chip-breaking region beyond the chip breaking limits determined by the prediction models in previous study. In this paper, the chip-breaking chart is studied for protruded insert grooves. Analytical models are established in order to determine minimum and maximum depths of cut in the additional region of the chip breaking chart. In the end, the analytical critical feed rate model is extended to the cases that the depth of cut is smaller than nose radius.

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