Numerical Simulation Aided Design of the Geometrical Parameters of the Chip Breaker for Grooving Process

Chip control is the core challenge of low feed grooving. Most of the existing research focuses on traditional materials, and there is a lack of systematic analysis of the interaction of chip breaker parameters. In this study, a 2D finite element model has been built to design the chip breaker for rough machining Fe–Cr–Ni stainless steel. The parameters of straight flat-type chip breaker were divided into four parts and the influence of these parameters on chip breaking was analyzed. It finds that the most important parameters are the length of the rake face and flat face, followed by the angle of the active face of the chip breaker, the least important parameter should be the length of the active face of the chip breaker. The small (large) length of the rake face combined with the large (small) length of the flat face is more reasonable to improve the chip breaker performance. For rough machining Fe–Cr–Ni stainless steel, the optimal length of the rake face and length of the flat face are [Formula: see text][Formula: see text]mm and [Formula: see text][Formula: see text]mm, [Formula: see text][Formula: see text]mm and [Formula: see text][Formula: see text]mm, [Formula: see text][Formula: see text]mm and [Formula: see text][Formula: see text]mm, while the optimal angle scope of the active face of the chip breaker is [Formula: see text]–[Formula: see text]. With the angle of the active face of the chip breaker increasing from [Formula: see text] to [Formula: see text], the tool stress remains constant at first and then increases at the larger feed rate. But the angle of the active face of the chip breaker has little influence on the tool stress when the feed rate is small.