Investigation of the relation between chip condition and built-up edge formation in dry orthogonal cutting of C45 steel
8th CIRP Conference on Surface Integrity, CIRP CSI 2026, Yokohama, Japonya, 19 - 22 Mayıs 2026, cilt.144, (Tam Metin Bildiri)
- Yayın Türü: Bildiri / Tam Metin Bildiri
- Cilt numarası: 144
- Doi Numarası: 10.1016/j.procir.2026.03.008
- Basıldığı Şehir: Yokohama
- Basıldığı Ülke: Japonya
- Anahtar Kelimeler: BUE, chip composition, dry cutting, turning
- Orta Doğu Teknik Üniversitesi Adresli: Evet
Özet
The formation of the built-up edge (BUE) is critical in machining ductile materials such as C45, particularly under dry conditions. It affects the surface integrity, tool conditions, and accuracy of the produced parts. The method to identify the stages of BUE formation without interrupting the process remains unclear. This work investigates the correlation of BUE formation during dry orthogonal cutting of C45 steel with uncoated carbide inserts to the chip characteristics. Firstly, by analysing the measured cutting force, the change in cutting-edge radius during cutting is explained by the BUE accumulation. Then, BUE formation stages are correlated with chip condition, including the presence of deformation bands, underside chip roughness and shear angle, and thickness, curling, chemical composition and colour of the chips. Two cutting tests were conducted at two feed rates and a constant speed. In each test, the chips were collected in three transient regions: Beginning, middle, and end of the cut. Then, each test is repeated under the same cutting conditions, and the produced chips were collected and analysed. In each transient region, five chip segments were collected and analysed. The cutting force reflects a change in process mechanics evidenced by radial force surpassing the tangential component during the cut, which is due to the increased cutting-edge radius with the continuous progression of BUE formation. The findings for the chip under these conditions indicate reduction in chip underside roughness along the cutting process, an increase in chip thickness, and straightening of the chip shape. The chemical composition analysis of the chip underside shows a decrease in carbon content and an increase in oxygen content as the cutting progresses. The chip colour indicates a transition from dark blue at the beginning of the cut to grey at the end. As a result, this study advances knowledge of the stages of built-up edge formation by investigating chip conditions. Image, application 1 Application 1