A Comparative Analysis of Machining Performance During Turning SS304 Stainless Steel Under Dry and Compressed Air Cooling Conditions

Chips are a natural result of machining operations, and handling and disposing of them is a key issue, especially when machining difficult-to-cut alloys. Therefore, it becomes crucial to conduct a thorough analysis of chip morphology considering the effect of cutting parameters, tool geometry, and cooling conditions. This research aims to understand the chip morphology, surface roughness, and cutting forces during turning SS304 stainless steel. To ensure a comprehensive analysis, trials were conducted under compressed air cooling and dry conditions. Experiments involve a range of feeds, including 0.1 and 0.3 mm/rev, and cutting speeds spanning 200 and 400 m/min, all while maintaining varying depths of cut at 0.1 and 0.5 mm. With a rise in cutting speed, it was found that the cutting forces and surface roughness were decreased, and chip thickness ratio, and the shear angle were increased. But as the feed rate and depth of cut increased, the cutting forces and surface roughness were increased, and chip thickness ratio, and the shear angle were decreased. To better understand how the cutting circumstances interact, this study also created a mathematical model to predict and visualize the chip thickness ratio and shear angle varying with the cutting conditions.