Decomposition of cutting forces with respect to chip segmentation and white layer thickness when hard turning 100Cr6

Abstract

This paper deals with hard turning of steel 100Cr6 with a hardness of C. Surface integrity expressed in terms of white layer thickness is studied as a function of tool wear and corresponding thermo-mechanical load of the machined surface. Total force is decomposed into components associated with the chip separation Fγ and the component Fɑ, which is associated mostly with the flank wear land. The results of experiments show that normal and shear components of the force Fɑ, increase progressively with the developed flank wear VB and correlate significantly with the white layer thickness. Furthermore, tool wear is also strongly dependent on the insert rake geometry, which contributes to the cutting force component of Fγ associated with the chip separation. For this reason, the chip formation depends on the progress of the tool wear.