FEM Based Design of a Chip Breaker for the Machining with PCD Tools

This paper presents a methodology to design and manufacture a chip breaker in a PCD turning tool. 

The objective is to avoid the surface roughness and chip evacuation problems produced by long chips in turning processes. An analysis of the process is made to design a suitable chip breaker shape for semi-roughing and finishing operations in aluminum turning. FEM simulation and experimental test are used to understand the chip formation and breakage processes leading to improved chip breaker geometry. The new designed geometries are micromachined with laser in the PCD tools, and the improvement in the chip control is proved experimentally.