AN INVESTIGATION OF THE EFFECTS OF CHIP FLOW ON TOOL-WEAR IN MACHINING WITH COMPLEX GROOVED TOOLS

This paper presents a systematic approach towards understanding of the tool-wear mechanisms in grooved tool inserts based on chip-how patterns. It has been observed through high-speed filming experiments and scanning electron microscopy that improper design of chip-groove geometry and/or inappropriate application of the cutting conditions result in ''undesirable'' chip-flow patterns and consequent rapid tool-wear and tool failure, especially in cases, where the flank wear (VB) or the crater wear (KT) are not severe, Thus, the different forms of tool-wear in grooved tools can be seen as more due to the mechanical action of the flow of the chip than due to the adhesion or diffusion process. The present work is expected to lead to a better understanding of the influence of individual chip-groove and machining parameters on tool failure modes, and consequently, would contribute to a more effective tool-life prediction.