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<p>Chip morphology significantly influences thermo-mechanical behaviour at the tool-work-piece interface, affecting tool life. During machining, chip morphology and segmentation dominantly influence material machinability. Hence, analyzing chip formation in cutting processes is needed to study material machining mechanisms. This study compares chip morphology during machining of AISI 52100 steel (high carbon chromium alloy steel) under various cutting conditions due to its hardness and wear resistance. Seven C-type and eight S-type advanced single and multilayer tools were used for machining. Design parameters for specific chips were assessed, showing significant variations in chip pitch, length, and diameter between S-type and C-type inserts and cutting tool materials. The continuous-discontinuous zone was chosen for best machinability results. Results suggest that balance between continuous and discontinuous chip formation is key in optimizing machining. A comparison of how different cutting tools influence chip morphology enabled understanding which tools are most effective under various machining conditions.</p>

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Dynamic chip morphology study of AISI 52100 by advanced coated cutting tools

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • Rashmi Ranjan Lenka,
  • Ayashkanta Jena,
  • Laxminarayan R Bhandarkar,
  • Saroj Kumar Sarangi

摘要

Chip morphology significantly influences thermo-mechanical behaviour at the tool-work-piece interface, affecting tool life. During machining, chip morphology and segmentation dominantly influence material machinability. Hence, analyzing chip formation in cutting processes is needed to study material machining mechanisms. This study compares chip morphology during machining of AISI 52100 steel (high carbon chromium alloy steel) under various cutting conditions due to its hardness and wear resistance. Seven C-type and eight S-type advanced single and multilayer tools were used for machining. Design parameters for specific chips were assessed, showing significant variations in chip pitch, length, and diameter between S-type and C-type inserts and cutting tool materials. The continuous-discontinuous zone was chosen for best machinability results. Results suggest that balance between continuous and discontinuous chip formation is key in optimizing machining. A comparison of how different cutting tools influence chip morphology enabled understanding which tools are most effective under various machining conditions.