Analysis of Chip–Tool Contact Length for Developed Centrifugal Cutting Tool and Conventional High-Speed Cutting Tool Using Predictive Models

Chip–tool contact length consisting of both sticking zone and the sliding zone is a very important characteristic during dry machining and affects both the cutting process and tool wear reflecting product quality. The predictive model is used to study the chip–tool contact length with varying the cutting conditions. In this paper, a mild steel workpiece is considered for experiment using two different cutting tools cast by two different techniques such as centrifugal casting and conventional casting for the sake of comparison. The result revealed, at a speed range of 30–50 m/min, the chip–tool contact length decreased with an increase in cutting velocity leading to a decrease in sliding zone and an increase in the sticking region. In this speed region, the centrifugal cast tool develops smaller contact length compared to conventional cast tool but after 50 m/min, the chip–tool contact length started increasing slowly in the centrifugal cast tool. At 60 m/min, the chip–tool contact length of centrifugal cast tool is observed very high compared to the conventional tool.