The efficiency of uncoated and coated tool systems in the machining of low carbon steel assessed through cutting force measurements

Experiments have been conducted on uncoated and coated carbide and ceramic lathe tool inserts of differing geometries at various speeds and feed rates. Each insert was tested for 20 s during which the cutting forces were measured with a Kistler three-component piezoelectric dynamometer and evaluated using a computer-based system, The experiments were carried out so that all variations in the tool forces were affected only by the mechanical properties of the tools. The effects of systematically varying coatings and tool geometries on cutting forces were analysed at specified time intervals. It has been established that the geometry of cutting inserts has a significant effect on the cutting force components. Uncoated carbide inserts produced fords about 15% higher than ceramic inserts, while 10% variations in cutting force component values were obtained from coated carbide inserts and ceramic inserts with different geometries. It was also found that in unstable cutting conditions ceramic inserts were associated with higher variation in force component values than carbide inserts. The prospects for the use of these kinds of data for adaptive control and tool design in quality manufacturing are discussed.