Advances in the turning process for productivity improvement — a review

Abstract

Increasing productivity and reducing manufacturing cost have always been keys to successful business. In machining, higher values of cutting parameters offer opportunities for increasing productivity, but this also involves greater risk of deterioration in surface quality and tool life. During the past decade significant advances have been made in the development of cutting tool materials for machining of ‘difficult-to-cut’ materials. The cost involved in the production of new turning tools is very high. To overcome this cost factor researchers have tried to bring about modifications in the turning process using existing tool materials. A good understanding of the cutting conditions, temperature generation, failure modes, and cutting forces leads to efficient control of the turning process. The literature reveals that modifications in the tool geometry (such as grooved/restricted contact tools (RCTs) and chamfered/honed edges), applications of cooling techniques, ultrasonic assisted turning (UAT), hot machining, and cryogenic treatment of inserts have led to efficient and economic machining of modern materials used for aerospace, steam turbine, bearing industry, nuclear, and automotive applications. This paper presents a review of the different techniques involved in turning which can supplement the performance of cutting tools for improved economics, good surface finish, and surface integrity during machining of the latest materials.