An energy approach to chip-breaking when machining with grooved tool inserts

The paper presents some interesting findings which contribute to a better understanding of chip-breaking using grooved tool inserts to machine steels in a turning process. Experimental investigations were carried out including measuring the cutting force, cutting energy and the temperature at the chip-tool interface together with identification of the chip form. The experimentally obtained results were used to correlate the transition from unacceptable chip forms to the chip-breaking area (acceptable chip forms) with a critical value of the specific cutting energy. In particular, it was shown that the interface control factor was one of the most important factors controlling the mechanism of chip-breaking. Based on the experimental results there was distinguishable uniformity in distribution of the total cutting energy for finish, medium and rough machining operations. The beneficial effect of controlling the cutting contact area, with respect of energy reduction, became more significant with an increase in feed rate. (C) 1997 Elsevier Science Ltd.