Analysis of Energy Consumption in the Cutting Zone During Turning Bearing Steel 16MnCr5

This paper deals with the consumption of energy during the turning of low-alloyed steel 16MnCr5. The study employs the earlier reported methodology for the decomposition of energy in cutting during turning. The energy for chip formation, as well as the energy consumed in the interface between the tool flank and produced surfaces, can be singled out. The paper investigates the turning process as a function of the cutting conditions as well as the variable cutting edge geometry. It was found that the integration of a chip former valuably contributes to the lower chip ratios, as well as the more favourable shape of chips. The lower energy consumed in the tool flank region for the tool with the integrated chip former results in lower normal and shear forces despite the higher cutting edge radius. However, the differences in the surface strain accumulation expressed in terms of the dislocation density and residual stress depth profiles are only subtle.