Effects of Tool Wear on Surface Roughness and Cutting Force in Thermoplastics Turning

This paper presents a study of the effects of tool wear on cutting force and surface roughness. The cutting force was measured using a piezoelectric force meter which was attached to the cutting machine's revolving head. The surface roughness was measured after the cutting process was complete using a mechanical touch method. A range of thermoplastic materials and cutting layouts were used to give a broader understanding of the topic. After the measurements were taken, the data were evaluated statistically and the effects of tool wear are illustrated graphically. Furthermore, to understand all of the types of wear which can occur during thermoplastics turning, worn turning inserts taken from industrial machines were examined under a microscope. The aim of the study was to define a method for monitoring tool wear during the turning process to avoid tool breakage and/or reduce the number of scrapped parts.