Abstract
The effect of cutting speed and wear land length on the surface damage produced during machining of quenched and tempered AISI 4340 steel under dry, orthogonal conditions was determined. Machined test pieces were examined with a scanning electron and optical microscope. Surface roughness was determined with a profilometer. The results of the investigation show that during machining considerable surface damage is produced; the intensity of which decreases with an increase in cutting speed and wear land length. It was found that the surface damage existed in a wide variety of forms which included chatter marks perpendicular to the direction of relative work-tool motion, long straight grooves parallel to the direction of work-tool motion, large cavities, workpiece debris, tool debris, plastic deformation, cracks, microcracks and voids. The results are interpreted in terms of the type of chip produced during machining and the interaction between the tool nose region and work piece. It is shown that scanning electron microscopy is more indicative of the true condition of the surface than surface roughness measurements.
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