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 patter ns. It has been observed through high-speed filming experiments and sc anning electron microscopy that improper design of chip-groove geometr y 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 c rater 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. Th e present work is expected to lead to a better understanding of the in fluence of individual chip-groove and machining parameters on tool fai lure modes, and consequently, would contribute to a more effective too l-life prediction.