An investigation into the effects of tool chip breaker geometry on the surface roughness and cutting forces in milling operation

In this study, surface roughness and cutting force measurements were performed according to the results of machining tests that were carried out on AISI 1040 carbon steel work pieces. The machining tests were performed by using a CNC vertical machining center equipped with a dynamometer, and machining the work pieces mounted on this dynamometer. Four different cutting tools (R390-11 T3 08E-PL 1030; R390-11 T3 08M-PL 1030; R390-11 T3 08M-PM 1030; R390-11 T3 08M-MM 2040) whose chip breakers have different geometry were used in the experiments. Cutting depth was set to 1 mm, feed rate was set to 0,05; 0,10 and 0,15 mm/tooth. Milling process as were performed with the cutting tools at four different cutting speeds (150; 225; 300; 375 m/min) using determined cutting conditions. Effects of each chip breaker geometry on machined work pieces in terms of surface roughness and cutting forces have been examined. In the end of the experiments, the best values of surface roughness and the lowest values of cutting force were obtained by using the cutting tools that have E-PL 1030 chip breaker form. According to the results, it was observed that surface roughness values increased with the increase of feed rate and decreased with the increase of cutting speed for all cutting tools. On the other hand, cutting force values have been increased with the increase of feed rate and decreased with the increase of cutting speed.