Study of cutting tool forces and nature of chip in turning of AISI 1040 steel

In the present study, the effect of variation of cutting speed (Vc), feed rate (s) and depth of cut (t) on cutting force (Fz), feed (axial) force (Fx) and thrust (radial) force (Fy) in machining of AISI 1040 steel has been investigated, keeping the rake angle and principal cutting edge angle unchanged. The nature of the chips obtained during machining and cutting tool condition after machining were also studied. The effect of feed rate on three components of tool force (Fz, Fx and Fy) was found to be maximum in comparison to cutting speed and depth of cut. The next influential parameter was depth of cut. However, cutting speed had the least significant effect on Fz, Fx and Fy. Small thin discontinuous chips were obtained at lower cutting speed and feed. At moderate cutting speed and feed rate, the chips became continuous and as cutting speed and feed reached their higher end, chips became curled fragmented and bluish black in colour. After machining the condition of the cutting tool was observed. There was severe delamination of the coating from the rake face. The flank wear was also high. EDX graph indicated that there was diffusion of iron from the underface of the chip to the tool rake face