Analysis of Chip Morphology in Heavy Milling of 508III Steel Considering Different Tool Wear Conditions

During the process of chip formation, the chip is subjected to extrusion pressure, friction, heat, and a strong chemical reaction. The chip's macro and micro morphology, to a certain extent, reflect the condition of the tool during the cutting procedure. Therefore, researching the macroscopic and microscopic morphology of the chip's surface in response to different tool wear conditions is of great significance to reproducing the cutting condition and analyzing the tool wear mechanism. This paper focuses on the chips formed by milling the difficult-to-machine material 508III high-strength steel. Firstly, the 508III steel milling experiment is carried out at the actual machining site to collect chip data under different tool wear conditions. Next, the free surface morphology of chips and the bottom surface morphology of chips are analyzed. Further, the chip edges are investigated, and their causes are analyzed. Finally, heavy milling 508III steel chip curl morphology analysis is performed. The research results play important roles in revealing the mechanism of tool wear and the relationship between chip morphology and tool wear. This information can be used to provide theoretical and technical support for monitoring the tool wear status based on chip morphology.