Analysis of Chip Formation of AISI 52100 Steel During Hard Turning with Newly Developed HSN2 Coated Carbide Insert

Study of chip morphology at high speed in hard machining is a very challenging task while machining hard materials. In the field of ecological manufacturing, the demand for eco-friendly manufacturing process is increasing day by day which produced quick growth of making profit for coatings and achieved better solution regarding environmental issues that occur while machining with lubricant. In the present study, a new coating material (HSN2) is used on carbide insert for turning material having hardness 55 HRC. Here, chip formation and its related analysis are carried out while turning hardened AISI 52100 steel. The chips during machining are collected at different cutting conditions. The chip morphology is analyzed by using optical microscope. The chip morphology like maximum and minimum chip thickness, chip length and localized shear angle are analyzed. Further, segmentation degree, shear angle and chip reduction ratio are calculated from analytical equations and their variation are studied.