Experimental analysis of chip-breaker geometry effects on cutting forces, thermal load, and surface quality in turning AISI 304 stainless steel

This study experimentally investigates the influence of chip-breaker geometry on cutting forces, temperature, material removal rate, chip formation, and surface quality during the dry turning of AISI 304 stainless steel. Three chip-breaker geometries (A, B, and C) were evaluated using a full factorial experimental design with spindle speeds of 500, 710, and 1000 r/min and feed rates of 0.08, 0.12, and 0.16 mm/rev. The results showed that increasing the spindle speed reduced cutting forces and maximum cutting temperature, whereas increasing the feed rate led to higher mechanical and thermal loads. Among the investigated geometries, chip-breaker type B exhibited the most favorable overall performance, reducing cutting forces and temperature by approximately 20–25% compared with types A and C while simultaneously improving the surface quality. Chip morphology analysis revealed that type A generated the smallest chip curl radius, whereas type B produced the lowest chip thickness, indicating more favorable chip-flow conditions and reduced chip compression. The experimentally measured material removal rate values for type B were approximately 35% higher than those of type A, although type C exhibited the highest material removal rate values at the expense of increased thermal loading. Overall, the results demonstrate that the chip-breaker geometry significantly affects the thermo-mechanical behavior of the turning process, and chip-breaker type B provides the most balanced combination of cutting performance, thermal stability, chip control, and surface integrity for machining AISI 304 stainless steel under dry cutting conditions.