Influence of Cutting Process Parameters on Chip Formation with CNMG120408-E-SC3 Inserts
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Abstract
Hard machining is a process increasingly endorsed in the manufacturing sector as a substitute for grinding and for production purposes. The critical technological parameters that govern this process include tool wear, machined surface roughness, cutting force, chip morphology, residual stresses etc. This study attempts to analyze the morphology and characteristics of chips produced during the hard turning of hardened alloy steel. The experiments were conducted using RSM Box Behnken Design. The range of each parameter i.e. cutting speed, feed and depth of cut is set at different levels for the analysis purpose. Macroscopic results of chip morphology were correlated with cutting process parameters. The results were evaluated and it indicated that the interaction of process parameters has a significant effect on the control of chip formation. The color of the chips changes from metallic to blue when the cutting speed increases due to heat generated at the tool-workpiece interface and carried away by the chips.