Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

Abstract

In today’s unmanned productions systems, it is very important that the manufacturing processes are carried out efficiently and smoothly. Therefore, controlling chip formation becomes an essential issue to be dealt with. It can be said that the material removal from a workpiece using machining is based on the degradation of material cohesion made in a controlled manner. The aim of the study was to understand the chip formation mechanisms that can, during uncontrolled processes, result in the formation and propagation of microcracks on the machined surface and, as such, cause failure of a component during its operation. This article addresses some aspects of chip formation in the orthogonal and oblique slow-rate machining of EN 16MnCr5 steel. In order to avoid chip root deformation and its thermal influence on sample acquisition, that could cause the changes in the microstructure of material, a new reliable method for sample acquisition has been developed in this research. The results of the experiments have been statistically processed. The obtained dependencies have uncovered how the cutting tool geometry and cutting conditions influence a chip shape, temperature in cutting area, or microhardness according to Vickers in the area of shear angle.