Saw-Tooth Chip Formation and Its Effect on Cutting Force Fluctuation in Turning of Inconel 718

Zhang, Song，Li, Jianfeng，Zhu, Xiaoli，Lv, Honggang

Journal：INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING

Abstract：

Chip formation and its morphology are important features of metal cutting, and they can yield much more important information on the cutting operations. Meantime, the cutting forces are the most commonly used on-line indicators to monitor the cutting process. In this research, the formation of the saw-tooth chips has been investigated in association with the fluctuation of the cutting force components under different cutting parameters in turning of Inconel 718 with (Ti, Al)N/TiN coated cutting tools under dry cutting condition. By means of the optical microscopy and the scanning electron microscopy (SEM), the saw-tooth chips are observed at high cutting speeds, which directly cause the cutting force components to fluctuate. Based on the frequency analysis, the segmentation frequencies of the saw-tooth chips and the fluctuation frequency of the cutting forces are very close to each other It indicates that the formation of the saw-tooth chips is one of the important factors leading to the periodical fluctuation of the cutting force components, even though the cutting parameters all keep constant in turning of Inconel 718.

Keywords:

Saw-tooth chip formation; Cutting force fluctuation; Frequency analysis; Inconel 718; Turning

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