Validation of the slip-line model for serrated chip formation in orthogonal turning under dry and MQL conditions

Abstract

In this study, the previously developed slip-line model for serrated chip formation was validated in orthogonal turning under dry and MQL (Minimum Quantity Lubrication) conditions. Face turning experiments were conducted on grooved AISI 304 austenitic stainless steel workpiece with tool inserts having cutting edge radius of 50 gm. The cutting force components and the maximum and minimum chip thicknesses were measured to validate the model. In dry cutting, the average prediction errors are 9.44%, 4.78% and 7.69% for cutting, thrust, and resultant forces, respectively. In machining with MQL, the average prediction errors are 10.79%, 11.49% and 2.46% for cutting, thrust, and resultant forces, respectively. In addition, the average prediction errors for maximum and minimum chip thicknesses are determined as 6.38% and 9.12% in dry cutting and 7.79% and 4.35% in MQL, respectively. (C) 2019 The Authors. Published by Elsevier B.V.