Built-up Edge Research Articles

Influence of surface roughness and thermal characteristics in turning operation using nanofluid lubrication

The turning operation is commonly used as a major material removal process in the manufacturing industry. The rate of heat generation during machining operation causes deprivation in the surface finish of the workpiece, reduction in tool life, localized melting of burr, which results in built-up edge (BUE), and therefore causes high cutting force, etc. Any manufacturing technique requires adequate lubrication to attain the optimum tool tip temperature. The nanofluid can be used as a lubrication fluid for controlling the temperature. In the present study, the experimental data for temperature and surface roughness is obtained at different workpiece rotation speeds at the same depth of cut and the same feed of the turning operation. It is observed that at temperature reduces by 25 % to 33 % compared with the dry run at the tool tip and workpiece at spindle speeds equal to 250 RPM, 420, and 710 RPM using the mixing of cutting oil + water + different proportions of Al2O3 nanoparticles. It is also observed that the surface finish is also improved by 11.26 % to 17.26 % at different spindle speeds with the use of nanofluid as a lubricating fluid.

A Comparative Performance Investigation of Single- and Double-Nozzle Pulse Mode Minimum Quantity Lubrication Systems in Turning Super-Duplex Steel Using a Weighted Pugh Matrix Sustainable Approach

This study investigates the performance comparison of machining of UNS S32750 super-duplex stainless steel under single- and double-nozzle pulse mode minimum quantity lubrication (MQL) conditions. The pulse mode MQL system delivers lubricant pulses at specific intervals. The Taguchi L9 design, with three factors and their three levels, was taken to perform the CNC turning experiments under both single-nozzle and double-nozzle MQL cooling environments. The surface roughness (Ra), tool-flank wear (VB), tool-flank temperature (Tf), power consumption (Pc), and material removal rate (MRR) are evaluated and compared as performance indicators. In comparison to single-nozzle MQL, the responses of Ra, VB, Tf, and Pc were found to be decreased by 11.16%, 21.24%, 7.07%, and 3.16% under double-nozzle conditions, respectively, whereas MRR was found to be 18.37% higher under double-nozzle conditions. The MQL pulse time was found to be an important variable that affects Ra, VB, Tf, and MRR significantly. Under both cooling scenarios, common wears such as abrasion, built-up edges, adhesion, and notch wear are detected. Furthermore, the Pugh matrix-based sustainability evaluation results revealed that the double-nozzle MQL technique was superior to single-nozzle MQL, achieving improved sustainability for machining super-duplex stainless steel.

The structure design and cutting performance research about the groove of the indexable inserts for machining stainless steel

Stainless steel is a notoriously difficult-to-machine material, with challenges such as hard-to-break chips and severe tool wear. To address these issues, a finishing indexable insert has been designed and developed specifically for stainless steel. This tool, named HMF, was compared to commercial tools (NF4, BF) in terms of its curved groove structure and cutting performance using SEM (scanning electron microscope Sigma500), 3D scanning (KEYENCE-VR 5000) and a profiler (Mitutoyo C-200). The HMF tool utilizes a curved edge with a curved chip breaker, and a chip-breaking bump on the tool nose. The groove parameters of the HMF insert are as follows: cutting edge angle of 12°, chip breaker groove width of 1.89 mm, back wall height of 0.095 mm, and anti-chip angle of 4°49’. 3D scanning of the chip break site reveals that the HMF chip break has a higher bump and a more pronounced chip rolling effect. HMF tool chip-breaking experiments show that it has ideal chip-breaking performance in the finishing range of ap = 0.6–1.0 mm, and f = 0.1–0.25 mm r−1. Chip analysis shows that the HMF chip curl frequency increases and the chip curl is tighter as the feed rate increases, and the curl radius gradually decreases when the feed rate is greater than 0.15 mm r−1. The results of the wear performance study are as follows: all three tools show rake face crater wear when cutting stainless steel. A small amount of built-up edge appears on the HMF cutting edge. The wear life of HMF is close to NF4 and better than BF; the wear of BF is faster in the later stages of wear.

Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

Micro milling offers the best way to create micro channels; however, the burr formation and surface roughness of the micro channel are difficult to control. Micro channel fabrication and their characterization of stir cast Al6061 are rarely investigated. In the present study, Al6061 alloy was processed by the bottom pouring stir casting method. The micro channels were fabricated on a base and stir cast Al6061 alloys using TiSIN-coated micro end mill tools. The influence of micromachining parameters such as spindle speed, feed rate, and depth of cut on burr formation, cutting force, burr size, and surface roughness was investigated. A comparison was made between the findings obtained from the micro milling of the base and stir cast Al6061 alloys. The surface morphology of fabricated micro channels was analysed and correlated with the roughness profile to understand the channel profile and burr formation. The top burr formation mechanism in stir cast Al6061 alloy was investigated in detail. Low feed rate, low depth of cut, and high spindle speed produced the micro channel with fewer burrs, low surface roughness, and low cutting forces. At the optimum parameter, stir cast Al6061 alloy showed an approximate 420%, 16%, and 300% increase in Fy, Fz, and Ra, respectively, as compared to the base Al6061 alloy. Adhesion wear, built-up edge, and microchipping were found to be the main tool wear mechanisms in micro machining of stir cast alloy. This study directs the choice of cutting parameters for the stir cast micro milling process.

Machinability and tribological analysis of used cooking oil for MQL applications in drilling AISI 304 using a low-cost pneumatic operated MQL system

Developing low-cost MQL systems and application of used/waste cooking oil (generated in restaurants/homes), which poses a health risk if it enters the food chain again, as feedstock for MQL applications can increase the adoption of MQL by smaller manufacturing industries. A low-cost pneumatic-based MQL system that works only on compressed air is developed and tested. The droplet size and velocity of the MQL aerosol are analysed using CFD to arrive at an optimum nozzle design and the nozzle spray characteristics are studied using a Phase Doppler Particle Analyzer. Drilling of AISI 304 using the MQL system with commercial MQL oil and used cooking oil is carried out and the results are compared with flood cooling. The thrust and radial forces are comprehensively analysed and related to the tool wear, built-up edge (BUE) formation along the drill cutting edges, and chip morphology. It is found that a steady drilling process is obtained with used cooking oil because of its superior viscosity (resulting in lower friction) and lower surface tension (leading to smaller droplet size and better wettability).

Assessment of self-lubricating coated cutting tools fabricated by laser additive manufacturing technology for friction-reduction

Dry cutting acting as a green machining technology is a promising manufacturing process in industrial applications; however, severe friction under dry cutting conditions aggravates tool wear and reduces tool life. Self-lubricating cutting tools exhibit excellent benefits in improving cutting properties and that can be used in sustainable machining. The complex process, low efficiency and thin coating thickness limit the production and use of present self-lubricating cutting tools with traditional methods. To enhance the lubricating effect and motivate the development of fabrication methods for self-lubricating cutting tools, Ni-based powders dispersed with MoS2 and Al2O3 particles were preset on the tool substrate; afterward, the self-lubricating coatings were deposited by laser powder-bed fusion additive manufacturing (AM) with a nanosecond fiber laser for cutting application. The self-lubricating coatings were characterized, and the friction and cutting performances of the AM self-lubricating coated tools (SLCs) were evaluated by sliding friction and dry machining tests. The results show that the developed SLC tools reduced the friction coefficient by 8.8–11.7%, cutting forces by 17.6–29.6%, and cutting power by 17.3–22.0% compared to conventional high-speed steel cutting tools (HSS). Built-up edge formation and tool wear were also significantly reduced. The observed mechanisms were attributed to the release of MoS2 particles from the coatings forming a lubricating film at the tool-chip interface, while the Al2O3 particles enhanced surface hardness. The results revealed the practicability of self-lubricating coated cutting tools fabricated by laser-based AM for friction-reduction, and that provide a cleaner process for dry cutting applications.

Research on the influence of single-crystal germanium cutting parameters based on molecular dynamics

As a metalloid with unique properties, single crystal germanium is widely used in semiconductors, infrared optics, and other fields. To ensure the processing accuracy of single-crystal germanium, it is necessary to optimise the selection of parameters during processing. This paper uses molecular dynamics methods to study the cutting process of single-crystal germanium with the cutting depth and cutting speed as parameters and uses nanoindentation method to test the mechanical properties of the processed single-crystal germanium surface. The study found that with the increase of cutting depth, the cutting force and cutting heat increased significantly, the depth of the deformed layer increased significantly, and the stiffness of single-crystal germanium decreased significantly; with the increase of cutting speed, there was no built-up edge Influence, the cutting force is reduced, and more cutting heat is generated, and the depth of the deformation layer is higher, and the HCP structure increases, but the cutting speed has no obvious relationship with the mechanical properties of the machined surface.

Monitoring Built-Up Edge, Chipping, Thermal Cracking, and Plastic Deformation of Milling Cutter Inserts through Spindle Vibration Signals

Condition monitoring provides insights into the type of damage occurring in the cutting tool during machining to facilitate its timely maintenance or replacement. By detecting and analyzing machining consequences (vibrations, chatter, noise, power consumption, spindle load, etc.), correlating them with different tool conditions enables real-time monitoring and the automated detection of tool failures. Machine learning (ML) plays a vital role in making tool condition monitoring (TCM) frameworks intelligent, and most research is geared toward classifying various types of tool wear. However, monitoring built-up edges, chipping, thermal cracking, and plastic deformation of milling cutter inserts are challenging and need careful consideration. To effectively monitor these phenomena, spindle vibrations can narrate the corresponding dynamic behavior of tool conditions and therefore have been investigated in this research. The acquired vibration data are then analyzed using histogram features and trained through the Partial C4.5 (PART) classifier to extract meaningful recommendations related to the milling cutter inserts condition.

Investigation of Cutting Performance of Nano/Layered Hard Coatings in Face Milling of AISI D2 Steel

In the die-molding industry, milling steels in a hardened condition is common. Tool wear and cutting-forces occurring during this process must be considered for better surface quality. The cutting performance of nano-layered AlTiN/TiN coated carbide cutting-tools in AISI D2 face-milling was evaluated in this work. Single-layer hard-coated carbide cutting-tools and uncoated cutting-tools were used to compare cutting performance testing. All cutting-speeds nano-layer AlTiN/TiN coated carbide cutting tool presented longer cutting-length than TiAlN and TiN coated ones and uncoated tool. Notch wear is an overriding wear mechanism, followed by build-up edge formation for all cutting-tools. Using a nano-layer AlTiN / TiN hard-coating, cutting-force values were lowered in all experiments.

Investigation of the surface quality and machinability of AISI 316LVM

Surface quality has a significant effect on the reliability of an implant. The surface finish of the workpiece is influenced by machining parameters, tool wear and cooling–lubrication conditions. Typically, mineral oil-based conventional cutting fluids are employed for cooling and lubricating purposes in industrial machining processes. However, the use of these fluids places costly environmental and health responsibilities on companies. Consequently, it is preferable to utilize an affordable and environmentally friendly coolant/lubricant that does not generate liquid waste or have harmful side effects. In this work, we conducted experimental investigations to examine the effect of cutting forces, cutting temperature, tool wear and the quality of the machined surface on the machinability performance of medical grade AISI 316LVM austenitic stainless steel. Five different cutting conditions were employed in the machining experiments: dry cutting, flood, minimum quantity lubrication (MQL), cryogenic cutting with liquid carbon dioxide (LCO2) and cryogenic cutting with liquid nitrogen (LN2). Compared to the dry-cutting condition, the cutting temperature decreased by 42.1% under LN2 and flood conditions and by 40.4% under LCO2 conditions. The cutting tools exhibited small amounts of flank wear and nose wear, along with the formation of built-up edges (BUE); however, no crater wear was observed. The MQL method resulted in the lowest cutting forces, while the cryogenic methods yielded the highest cutting forces. Among the cutting conditions, the MQL and flood conditions produced the lowest roughness values and the best surface quality. Conversely, the cryogenic cutting conditions led to the highest roughness values and the poorest surface quality. Furthermore, the MQL condition resulted in the lowest dimensional deviations.

Comparison of Machinability Performances in Milling of Al-7Si-Mg and Al-7Si-0.6Mg Alloys

In this study, the microstructural, mechanical and machinability properties of Al-7Si-Mg and Al-7Si-0.6Mg casting alloys were experimentally researched. While the microstructures of the alloys were determined by optical microscope, the hardness values were determined by Brinell method, elongation to fracture, yield (YS) and tensile strength (TS) values were measured by tensile tests. Milling experiments were performed 6 mm diameter of uncoated carbide end mill which two flutes in CNC vertical machining center using different cutting speeds (V), feed rates (f) and a constant depth of cut (DoC). In microstructural examinations, it was observed that the microstructure of the Al-7Si-Mg alloy comprised of a-Al, primary Si, eutectic Al-Si, Mg2Si, B-Al(Fe, Mn)Si, β-Al5FeSi and π-AlSiMgFe phases. In addition to the existing phases, B-Al8Mg3FeSi6 phase was formed in the microstructure of the Al-7Si-0.6Mg alloy. Al-7Si-0.6Mg alloy exhibited higher hardness, YS and TS and lower elongation to fracture (EF) values compared to Al7Si-Mg alloy. In the milling tests, it was stated that the cutting force (CF), built-up layer (BUL) and builtup edge (BUE) reduced with the increment of the V, while it increased with the increment of the

Experimental Assessment of Hole Quality and Tool Condition in the Machining of an Aerospace Alloy

This paper deals with an experimental investigation of hole quality in Al2024-T3, which is one of the aerospace alloys used in aircraft fuselage skin due to its high level of resistance to fatigue crack propagation. The experiments are conducted with 6 mm uncoated carbide and HSS drill bits using a CNC machine under dry conditions and different drilling parameters. The characteristics of the hole quality are investigated in terms of its perpendicularity, cylindricity, circularity and hole size. An ANOVA (analysis of variance) and Pareto charts are used to analyze the effects of the drilling parameters on the hole quality. The hole quality is also assessed using a digital microscope to observe the formation of hole burrs. Moreover, scanning electron microscopy is also used to investigate the inside-hole surface defects. Further investigations are carried out using optical microscopy to inspect the post-drilling tool condition at high drilling parameters. The results show that hole quality reduces as the feed rate and spindle speed increase. However, from the ANOVA results and Pareto charts, the influence of the feed rate on the hole quality is found to be insignificant. At the same time, the type of drill bit material shows the highest percentage of contribution affecting the hole quality, following the spindle speed. The HSS drill bit shows more adhesion and built-up edges than the uncoated carbide drill bit. There were more burrs formed at the hole edges when the holes were drilled with uncoated HSS drill bits. In the same way, the SEM analysis reveals more surface deformation and damage defects inside the hole walls of holes drilled using the uncoated HSS drill bit.

Performance evaluation of high-pressure cooling by using external rotary liquid applicator in milling Ti–6Al–4V alloy

An effective cooling mode with appropriate process parameters can enhance the machinability as well as productivity. In this regard, this study focuses on evaluating the machinability of widely used Ti–6Al–4V alloy with the use of high-pressure coolant jets compared to dry milling. A novel rotary applicator was designed and developed to feed high-pressure coolant jets without any drastic change of solid end mill cutter. Four flutes solid HSS end mill cutter was selected for machining because of its some intensive properties. Biodegradable VG-68 cutting oil was chosen as cutting fluid due to its better thermo-physical properties with higher flash points. Machinability was assessed at 16–32 m/min cutting speeds and feed rates of 0.08–0.16 mm/tooth with a constant depth of cut of 1.0 mm, taking into account the average cutting temperature, resultant cutting force, mean surface roughness, and tool wear. Dry milling produced the worst results for all of the investigated responses, with excessive tool wear due to the lack of cooling and lubrication. Compared to dry milling, high-pressure cooling (HPC) lowered average cutting temperature, resultant cutting force, and mean surface roughness by 11.21–21.57%, 8.63–13.12%, and 6.09–29.6%, respectively, whereas rotary high-pressure cooling (RHPC) reduced these parameters by 15.39–27.27%, 14.05–21.18%, 16.48–41.04%. RHPC's efficient cooling and lubrication increased the machinability of the Ti–6Al–4V alloy. Dry milling showed severe flank wear with increased built-up edge (BUE) development, abrasion, and adhesion, whereas HPC and RHPC dramatically reduced the severity of tool wear. In HPC and RHPC, the tool life was consequently increased by 6.8 and 9 min, respectively.

Machining of Hard-to-cut AISI 4462 Duplex Stainless Steel with an Environmentally Friendly Approach with Vortex Tube

Machining is a manufacturing process that can be used to produce precision machine parts and has many advantages. The first is the ability to achieve superior surface quality. Tool wear is an inevitable phenomenon that occurs during machining. It is affected by many machining conditions; therefore, this process needs to be monitored and controlled. In this study, tool wear and surface roughness tests were carried out on AISI 4462 duplex stainless-steel materials, known to be a hard-to-cut material. For this purpose, tool wear and surface roughness analyses were implemented by using the environmentally friendly vortex tube cooling system in addition to wet turning conditions for the first time. For both methods, experiments were conducted at a 1 mm depth of cut, 120 m/min cutting speed, and 0.1 mm/rev feed with a 90 mm cutting length for each pass. Both tool wear and surface roughness were examined at the end of each pass. The analysis showed that wet turning gave better results in terms of tool life (19.8 minutes of tool life) compared to 11.1 minutes of tool life in vortex turning. In contrast, the surface roughness values differed up to two times in some experiments, and the vortex tube experiments gave better surface roughness values in all passes. In addition, the vortex tube experiments showed less built-up-edge (BUE) formation than the wet-turning experiments.

A STUDY OF THE PHENOMENON BUE CREATION IN TROCHOIDAL MILLING

Aluminum alloy 6061-T6 is a commonly used material in various industries, including automotive parts manufacturing. However, its machining process can be challenging due to the occurrence of build-up edge (BUE) at the cutting edges. To address this issue, this research employed trochoidal milling to machine aluminum alloy 6061-T6 specimens, utilizing a small step over and a suitable depth of cut. The engagement of the tool during the machining process generates fluctuating forces, which consequently leads to fluctuations in temperature. This phenomenon is not only observed in trochoidal milling but also in conventional machining methods. The results indicate that the calculated maximum temperature (350°C) is lower than the aluminum's melting point (652°C). Moreover, the experimental results show minimal BUE formation on the cutting edge and an improved milling process.

Orthogonal turning of AISI 310S austenitic stainless steel under hybrid nanofluid-assisted MQL and a sustainability optimization using NSGA-II and TOPSIS

AISI 310S austenitic stainless steels are widely used in many industries, such as oil, gas, and petrochemical industries containing hot concentrated acids, due to their superior properties like corrosion resistance, high-temperature service, and creep resistance. However, a study on the machining of AISI 310 stainless steel has not been published in the scientific literature. It is known that the machinability of the austenitic stainless steel alloys, in which the AISI 310S alloy is included, is poor due to its low thermal conductivity, high work hardening, and built-up edge (BUE) formation. This situation causes sustainability problems by increasing the energy consumptions, the total machining cost and the amount of carbon emissions. The presented study investigated for the first time machining response and sustainability assessment in the orthogonal turning of AISI 310S stainless steel using three different cutting speeds and feed values, and five different cutting conditions such as dry, vegetable-based fluid minimum quantity lubrication (MQL), nano molybdenum disulfide (nMoS2) reinforced nanofluid MQL, nanographene (nGP) reinforced nanofluid MQL, and nMoS2/nGP reinforced hybrid nanofluid MQL, and a sustainability optimization was performed. Sustainability optimization was conducted to minimize the resultant force, surface roughness, carbon emission, and total machining cost using multi-objective optimization with NSGA-II (Non-dominated Sorting Genetic Algorithm II) and multi-criteria decision-making with TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution). The resultant force, surface roughness, total carbon emission, and total machining cost were reduced by a significant, 56.8%, 86.8%, 30.4%, and 2.9%, respectively, under the nGP reinforced nanofluid MQL cutting condition compared to the dry cutting condition. As a result of sustainability optimization, the use of high cutting speed (220 m/min), low feed values (between 0.11 mm/rev and 0.14 mm/rev), and nGP reinforced nanofluid MQL method (N2-MQL) in the turning of AISI 310S stainless steel material provides the optimum surface roughness values, cutting forces, carbon emissions, and total machining costs.

An adaptive method of measuring the rake face wear of end mills based on image feature point set registration

An acceptable tool wear evaluation and acquisition approach is critical for developing an accurate, rapid, and practical online tool wear prediction system. The one-dimensional crater wear depth is difficult to quantify, and relying solely on flank wear width is very simplistic. External conditions such as vibration and illumination have a large impact on two-dimensional wear area and three-dimensional volume. In practice, these are difficult to successfully characterize tool wear. This work proposes a two-dimensional rake face edge loss area as an additional indicator to assess milling cutter wear. An adaptive measurement approach based on 2D image feature point set matching is presented to suppress the area calculation error caused by image position offset and chips or built-up edges. 201 images were collected in two groups of cutting experiments for comparison with the proposed method and the other two methods, manual registration and non-registration. The results show that the proposed method's measurement values are closer to the actual values and have a higher measurement efficiency. Furthermore, the proposed indicator is sensitive to micro-scale changes to the blade edge, especially at the tip, and can be used as a supplement one to monitor tool wear more comprehensively.

Comparative study of drilling super austenitic stainless steel with external applications of reduced quantity nanofluid and flooded bio-lubricant

AISI 904L is a super austenitic stainless steel (SASS) with excellent corrosion resistance and good mechanical strength at high temperatures that can be applied in extreme operational conditions. Consequently, it has low machinability. Research involving SASS drilling is scarce in the literature. Thus, this work aims to evaluate the TiAlN-coated carbide drill life associated with thrust force and torque in the full-hole drilling of the Ultra® 904L under external lubrication with a 100-mm/min feed rate. Nanofluid-based reduced quantity lubricant (2.0 L/h) at 840-rpm spindle speed and flood bio-lubricant conditions (540 L/h) at 840- and 1260-rpm spindle speeds were applied, totaling three tool-life tests. Digital image analysis showed that the failures in the main cutting edges occurred due to chipping resulting from the rupture of the built-up edge. The drill wear did not reach expressive values. Low tool life was observed with nanofluid in reduced quantity (E1 test, 0.67 min) and flood condition with 1260 rpm (E3 test, 1.34 min). The longest drill life was registered for 840 rpm with flood biofluid (E2 test, 8.04 min). Lastly, a growth of 11% in thrust force and 9% in torque were noted when increasing the lubricooling flow from the E1 to E2 test; however, there was a reduction of 31% and 42% when raising the spindle speed from E2 to E3 test. The flood condition resulted in a longer drill life and smaller thrust force and torque values (at least 20% lower), which are associated with chip deformation, hardness, and friction coefficient reductions due to increased cutting speed and temperature. Moreover, built-up edges were formed during the drilling of all the holes.

Study of cutting force in turning of AISI- 304 steel using mono and hybrid graphene nanoparticles enriched cutting fluid

In manufacturing industries turning hard materials like AISI 304 steel is very challenging because of its low ability to heat dissipation. When these kinds of materials are perform machining, heat builds up on the tool tip, this raises the temperature of the tool tip which speeds up the rate of tool wear. So present investigation based on turning of hard material AISI-304 strain-free steel using Al-GrP based hybrid nanofluids and graphene-based nanofluids in vol. concentration 0.25, 0.5 & 0.75 vol% with the base oil sunflower oil. RSM with Box-Behnken was utilized in this experiment's design and response analysis. It was observed that the hybrid nanofluids made of Al-GrP (with nanoparticles fraction 80:20) and graphene had a reduced wettability, which affected the heat dissipation rate. This supports by the DSA test results of several nanofluids on tooltip surfaces. In Drop shape analyzer (DSA) results show that the contact angle at the tool insert in Al-GrP nanofluids is smaller than that of graphene-based nanofluids at the same concentration. During the experiment, it was discovered that Al-GrP and graphene have the shortest contact angles at 38.9° and 41.9° at 0.75 vol%.The use of (Al-GrP) hybrid nanofluids with MQL lowers surface finishing by 10%, as well as the force on cutting direction is 7.25 percent, respective compared to graphene-based nanofluids, and Graphene also demonstrates a high rate of tool wear, which forms a built-up edge on the tool during machining of AISI-304 strain-free steel.

Effect of casting modification materials on cutting forces of an Al12Si alloy used in aircraft technology

Abstract In this study, the effect of modification Al-12Si (Etial 140) casting alloy with Al10Sr, CuSn5, and Al10Sr + CuSn5 master alloys has been investigated with respect to the cutting forces. In order to characterize the morphology of materials used in this study, metallography, hardness, density tests, and chemical analysis were performed. An optical microscope was used to examine the microstructure of the samples. Machinability tests were performed with the turning method by using a titanium diboride-coated cementite carbide cutting tool. All experiments were carried out under dry machining conditions with three different cutting speeds and feed rates with a constant cut depth. After the turning test, scanning electron microscope (SEM) images were used to examine the build-up edge (BUE) formation on the cutting tool. It was determined that the modification process has a positive effect on increasing the density and hardness. According to the results, it was observed that cutting (Fc), feed (Ff), and tangential (Fr) forces decreased for all material groups with increasing cutting speed V. Furthermore, Fc, Ff, and Fr forces increased for all material groups with increasing feed rate f. Finally, the highest cutting forces were observed on the Etial 140 c + Al10Sr master alloy.