Effect of rake face surface of cutting tool on tool crater wear

Abstract

Tool wear is complex to predict due to the intricate environment of a machining process. However, there are a confrontational effect of tool wear on the machining process in terms of deprived surface finish, reduced dimensional accuracy and increased power consumption. In this study an attempt is made to examine the effect of rake face surface of the cutting tool on tool crater wear. For this, three different types; uncoated, coated and structured rake face cutting tools were used and cutting test were performed of plain carbon steel (AISI/SAE 4140). The cutting speed of 283m/min, feed rate of 0.1mm/min and depth of cut of 0.1 were used. Results show, structured rake face of the cutting tool benefitted most in supressing the tool crater wear. Energy-Dispersive X-Ray analysis (EDXA) analysis confirms reduction in iron transfer on tool rake face in case of coated and structured cutting tool. Micro - hardness test was also performed and the values in case of coated and structured cutting tool was found to be suffice. This study can be a benefit for cutting difficult to cut material where crater wear formation is unavoidable.