The effect on the cutting tool stresses of the different chip breaker form in turning

THE EFFECT ON THE CUTTING TOOL STRESSES OF THE DIFFERENTCHIP BREAKER FORM IN TURNING(M.Sc. Thesis)Hüseyin GÜRBÜZGAZI UNIVERSITYINSTITUTE OF SCIENCE AND TECHNOLOGYDecember 2006ABSTRACTIn this study, the effect of the different chip breaker forms used in the turningprocesses on the cutting forces and the tool stresses was investigatedexperimentally. AISI 1050 carbon steel and the cemented carbide with an ISOdesignation SNMG 120408R has the inclination angle 75 degree was used asworkpiece material and the cutting tool, respectively, in the cutting tests. Theinserts were mounted on a tool holder with an ISO designation PSBNR 2525.The coated MA, SA, MS, GH, and Standard (STD) and the uncoated MS, andSTD forms was selected as the chip breakers according to the workpiecematerial. They are manufactured by Mitsubishi and has UC6010 and UTI20Tgrade. The cutting forces occurred during metal cutting were measured by9257B Kistler dynamometer. The effect of the chip breaker form on the cuttingforces was experimentally determined according to various cutting parameters.The effect of the cutting forces exchange according to the chip breaker form wasanalysed by ANSYS based on the finite element method. The highest cuttingforce values were measured on the chip breaker form SA. The coated insertsexposure to the higher stress in comparison to the uncoated, but especially inthe heavy machining conditions, this is adverse. In the analyses, the maximumand minimum principal stresses (S1 and S3, respectively) and von Mises stresses(SEQV) were investigated on the cutting tool. In general, the chip breaker formsthe coated SA, and MA and the uncoated STD bring about the maximum andthe minimum values of the stresses, respectively.Science Code: 708.3.028Key Word : Turning, chip breaker, cutting forces, cutting tool stress,ANSYS, AISI 1050Page Number : 103Adviser : Prof. Dr. Ulvi ŞEKER