Investigation of the shearing length in the orthogonal turning of a steel AISI 1050

Abstract

Vibration amplitudes in machining operations have a deteriorating influence on the outcomes of the processes. Moreover, eradicating them is an impossible task due to the natural mechanism of cutting metals. However, by selecting the optimum cutting parameters, the destructive effects of vibration amplitudes may be diminished to acceptable levels. In the present paper, AISI 1050 steel material was machined, employing carbide inserts and a CNC lathe machine. Cutting tool approaching angles were selected between −5° and 45°, feed rates from 0.1 mm × rev^-1 to 0.5 mm × rev^-1, cutting depths between 0.5 mm and 2.25 mm, and accordingly CSR values between 1 and 15. The effect of the selected parameters on the chip compression factor (CCF), shearing length feed (SLF), shearing length (SLA), surface roughness, and chip morphology was investigated. Moreover, the effect of CCF, SLF, and SLA on surface roughness, vibration amplitudes, and chip morphology was analyzed as well. It was found that the most influential parameter on shearing length was cutting depth while the feed rate was on the surface roughness. The optimum CCF values were between 1.7 and 2.3, SLF smaller than 1, and SLA around 5. Furthermore, it was shown that the optimum CSR values were 10 and 15, and cutting tool approaching angles 30° and 45°, according to the chip morphology criterion.