Impact of Surface Modification Techniques for Replaceable Cutting Inserts on Cutting Forces and Surface Finish in Machining Operations

Abstract This study investigates the impact of surface modification techniques, specifically microblasting and Magnetorheological Finishing (MRF), on the performance of uncoated sintered carbide replaceable cutting inserts (RCIs) during machining operations. The primary focus is on the relationship between surface roughness modifications and two key performance metrics: the quality of the workpiece surface finish and the cutting forces generated during turning operations. The study involved controlled experiments using RCIs that were untreated, sandblasted, or MRF-treated. Microblasting was found to increase surface roughness, leading to higher cutting forces and poorer workpiece surface quality. Conversely, MRF treatment reduced surface roughness, resulting in lower cutting forces and improved workpiece surface finishes.