Impact of Chip Breaker Geometry on the Performance of Actively Rotary Monolithic Turning Tools

The control of chip formation is a key aspect of modern turning operations, as improper chip formation can negatively affect tool life, surface quality, and overall machining efficiency. One approach to improving chip control is the integration of a chip breaker into the geometry of the cutting tool. This study examines the impact of chip-breaking geometry on the performance of monolithic rotary tools in active rotation turning. Two types of tools were compared: one without a chip breaker and another with an integrated chip breaker. The functionality of the chip breaker was experimentally validated, demonstrating its effectiveness in shaping chip segmentation under specific process parameters. Furthermore, tool wear, workpiece surface roughness, and cutting forces were evaluated. The findings indicate that the tool equipped with a chip breaker exhibits reduced wear while maintaining comparable surface quality. However, this benefit is accompanied by a slight increase in cutting forces.