The effect of chip breaker geometry on chip shape, bending moment, and cutting force: FE analysis and experimental study

Control of continuous chips in turning operation is a very vital issue to enhance productivity and operator safety. A famous method to control the chip size is utilization of chip breaker. In this study, the influence of different aspects of chip breaker geometry on cutting force, chip shape, and bending moment was evaluated by using finite element and experimental approaches. Therefore, cutting tests were carried out on AISI 1045 steel using tungsten carbide inserts with various chip breaker geometries. The results indicated that the predicted cutting force and chip shape are in close agreement with the experimental ones. It is also observed that the bending moment generated by the upper level of breadth surface has the highest contribution in the development of combined and nonuniform state of stress at the root and body of deformed chip. Meanwhile, the chip breaker geometry had a significant effect on the cutting force value.

Orthogonal cutting; chip breaker; chip shape; simulation; bending moment; cutting force