Pedro A. R. C. Rosa

Metal cutting processes involve severe frictional conditions at the tool-chip contact interface, physico-chemical phenomena that are not fully understood and theoretical models with a strong empirical basis. In the literature, it is common to find values for the friction coefficient which are higher than the unit, despite the inconsistency of these findings with the mathematical theory of plasticity used for accurate modelling of the chip formation mechanics. Thus, the present work seeks to contribute to a better understanding of metal cutting tribology based on well-controlled and specially designed experimental conditions. To enable the stress state at the contact interface to be determined and to provide a known real contact area, polished cutting inserts with prepared rake faces were used to restrict the contact length in orthogonal cutting tests under controlled atmospheres. These conditions also allowed the contribution of the sticking mechanisms to be minimized. Cutting tools of restricted contact lengths have been found to reduce process forces and the friction coefficient, while industrial standard inserts make cutting operation sensitive to the chemical composition of the surrounding atmosphere.