Abstract

This paper presents a mechanistic model for the kinematics of chip formation during machining of hardened steel. In this model, the concept of crack initiation at the workpiece free surface is presented. Experimental work has been conducted in order to study the morphology of the chips collected from dry hard turning. The effects of cutting speed and feed on chip segmentation spacing and chip thickness are examined. The chip segmentation frequency is calculated and examined as a function of feed and cutting speed. A strong correlation between chip segmentation frequency and the cutting force fluctuation frequency is observed. Microhardness tests are also performed on all the chips collected. The experimental observations show that different combinations of cutting speed and feed have a significant effect on chip microhardness distribution.

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