A novel methodology to characterize tool-chip contact in metal cutting using partially restricted contact length tools

A novel methodology to map the friction and normal stress distribution on the rake face using Partially Restricted Contact Length Tools in orthogonal cutting tests is proposed. The influence of cutting speed, feed and coatings on tool-chip friction when machining AISI 1045 is analysed. The results demonstrate that the new methodology can replace the more difficult to use and less robust split-tool method. They confirm two clearly different contact zones: i) the sticking region, governed by the shear flow stress of the workpiece and ii) the sliding region, where the friction coefficient is higher than 1.