Effect of Cutting Insert Shape and Roughness on Built-Up Edge Formation When Cutting Steel AISI 316L

In general, the properties of alloy steels and special steels provide significant advantages to the end product. However, these properties often complicate the machining process, particularly in terms of machinability. The formation of a built-up edge (BUE) is a widely recognized phenomenon in the machining of austenitic stainless steels. It is closely associated with changes in cutting performance, tool wear, and surface integrity. Complex adhesive and plastic deformation processes drive BUE development under severe contact conditions at the tool–chip interface. Consequently, the geometrical characteristics and surface roughness of cutting inserts are expected to significantly influence the initiation and growth of adhered material layers on the cutting edge. The insert shape dictates the cutting forces and chip flow. In contrast, insert roughness (and micro-geometry) strongly influences friction and material sticking at the tool–chip interface. This article analyzes the processes in the material-tool contact system and their relationship to geometry, rake-face surface parameters, and BUE development when turning AISI 316L steel under dry and minimal lubrication conditions. The results indicate that BUE development is associated with the combined effects of chip-breaker geometry, rake-face roughness parameters (Rq, Rsk, and Rku), and cutting conditions. Cooling, including the use of an ionic liquid–water suspension, reduces the insert’s susceptibility to adhesion.