In the machining of difficult-to-cut alloys, such as titanium-based alloys, the delivery of a cutting fluid with high pressure can increase machining efficiency and improve process stability through more efficient chip breaking and removing. Proper selection of machining conditions can increase the productivity of the process while minimizing production costs. To present the influence of cutting fluid pressure and chip breaker geometry on the chip breaking process for various chip cross-sections Grade 5 ELI titanium alloy turning tests were carried out using carbide tools, H13A grade, with a -SF chip breaker geometry under the cutting fluid pressure of 70 bar. Measurements of the total cutting force components for different cutting speeds, feeds, and cutting depth in finishing turning were carried out. The analysis of the obtained chips forms and the application area of the chip breaker have been presented. It was proved that for small depth of cut (leading to small chip cross-section) the cutting fluid pressure is the main cause of the chip breakage, since the insert chip breaker does not work. On the other hand, for bigger depths of cut where the chip breaker goes in action, the cutting fluid pressure only supports this process. For medium values of depths of cut the strength of chip is high enough so that the pressure of the cutting fluid cannot cause chip breaking. A chip groove is not filled completely so the chip breaker cannot play its role.

This article presents investigations related to the turning of stainless steel as a representative of difficult-to-cut materials and the effectiveness of selected chip breakers working in the local machining environment. Martensitic steel AISI 416 was used to test two commercially available types of chip breaker. The efficiency of a chip breaker working in the range of cutting conditions recommended (by the tool manufacturers) was the aim of the turning tests. As a result of the investigations an algorithm of cutting condition selection, combining both the cutting tests and the simulation procedure for the efficiency of the chip breaker was created. The vision system, equipped with a high-speed camera was used for chip form estimation. Simultaneously, the cutting force components were measured to check if the simulation calculation was correct. The FEM simulation was applied to estimate the manner in which the chip groove was filled. The article presents certain recommendations for cutting condition correction in the local machining environment for the purpose of achieving an acceptable chip form.

The paper concerns the problem of energy savings in turning of titanium alloy Ti6Al4V. Since this alloy belongs to difficult to cut materials, there is a problem with chip forming and breaking. The turning process is often supported by implementing a high-pressure cooling (HPC) system. Based on the observations and the adopted chip classification method, the authors proved that it is not necessary to use this method in roughing operations, however it helps with the chips breaking process in finishing operations. A general algorithm for machining optimization due to the chip geometry is presented and described. In the presented case, it was shown that the acceptable chip geometry could be obtained with a reduced power consumption by approximately Pc = 0.5 kW. The authors concluded that it was not necessary to apply cutting data and a coolant system to achieve perfect chip geometry. An acceptable form was often sufficient, while requiring less energy. An additional factor resulting from the operation of systems supporting the cutting process, such as an HPC device, should be taken into account in the formula concerning the energy consumption (EC) of a computerized numerical control (CNC) machine tool.

The paper deals with longitudinal turning of Inconel 625 as a representative of difficult - to - cut materials. Two chipformers were tested on especially prepared research stand in the range of tool manufactures recommendations concerning depth of cut and feed. Chip form creation process was observed by means of high speed camera recording system. Then, the chips were evaluated and classified into three groups. The results are presented in the form of diagrams and tables. They show poor effectiveness of chipformers acting in small values of feed. A few examples of chip breaking sequences are presented. An algorithm leading to correct cutting data selection has been proposed. The algorithm uses a simulation procedure to verify chip groove filling in off line procedure.