Investigation of influence of approach angle and chip slenderness ratio on vibration, chip formation and surface quality in turning of AISI 1050 steel

Abstract

Machining method and its outcomes are significant in manufacturing operations, but determined vibrations in the process, quite hard to solve, rising from the natural mechanism of the process. Numerous parameters affect the machinability outcomes, such as surface roughness, chip morphology, tool wear, and fluctuations in the process. In this paper, 15°, 30°, and 45° approach angles, 1, 3, 5, 10, and 15 chip slenderness ratios (CSR), selected as the ratio of the cutting depth to the feed rate, were selected. Therefore, the effects of the cutting edge approach angle and CSR on the conclusions were investigated. At 15° approach angle, the severe and unstable vibrations were recorded, including the cracks, the chip serration with high pitch size, hard distortion cracks, and the largest tool wear areas which were observed on-chip morphology, but only at low CSR values and 45° approach angle. The highest fluctuations were taken place in the direction of cutting depth (X), for all selected parameters. The optimum results were recorded at 30° approach angle and 15 CSR, but the hardest deformation cracks seemed at 1 CSR. Additionally, Co, involved in the structure of the cutting tool as a binder, transfer to the removed chip, while Fe, from the workpiece to the cutting tool, during the process.