Modelling and Analysis of Tool Edge Chipping at the Initial Stage of Interrupted Turning Considering the Effects of the Adhesion

Tool edge chipping occurs easily in the interrupted turning operation, and it causes the increase of the cost and time of machining process and the reduction of machined surface quality. Meanwhile, the adhesion formation is a well-known phenomenon in metal machining. This study presents the results of an investigation of tool edge chipping produced by the adhesion formation and develops an analytical model to predict tool edge chipping in interrupted turning stainless steel SUS304. To promote the adhesion formation, an uncoated cemented carbide tool was used as the cutting tool. The effects of the adhesion on the cutting process were examined by use of both a high-speed camera (HSC) and a 3-component piezoelectric dynamometer. After the cutting test, the damages at the tool edge were observed through scanning electron microscopy (SEM). The experimental results show the adhesion formation has the significant influences on the chip formation process and tool edge chipping formation process. The stable adhesion formed at the tool-chip interface has the tool edge protective effect. To verify the experimental results, an analytical model is developed using both B. Paul's stress criterion and finite element method (FEM). The simulations show very good agreement with the experimental results.