Abstract:
The need for finishing operations have become even more significant with the
continuing trends in near net shape manufacturing. This requires finish
machining as the only form of machining aimed at imparting quality into the
manufactured component. Accordingly, tool inserts having two different nose
radii were purchased from a wide range of commercially available carbide/cement
chip groove combinations and tested for machining performance. Finish machining
operations are characterized by high cutting speeds, low feeds, and low depth of
cut. In our experimental work, we decided to cover a wide range for both the
feed and the depth of cut. Chips were collected and mounted on chip control charts and cutting forces were recorded for all test conditions, in order to develop a total understanding of the various chip flow mechanisms and the corresponding cutting power rates and surface finish requirements for designing optimum chip grooves.