In order to improve the performance of the cutting tool, it is required to model the metal cutting process at the system level. To predict and enhance the cutting tool performance the primary requirement of the system is the efficiency of the model explaining the interactions at the tool chip interface. The predominating parameters which influence the development of the system are work piece material and machining variables or sometimes both. Further the development of low cost methodology to study the chip tool interactions with minimum amount of testing is of more importance. Major part of the work is emphasized on the investigation and characterization of various zones on the rake face of tungsten carbide inserts. Tests have been carried out by machining AISI 1040 steel using WC inserts with variable dry conditions examining the chip flow phenomenon on the rake face of considerable number of samples. Taguchi method is adopted for the design of experimental conditions. Results have shown an acceptable chip flow patterns and authors were able to quantify the wear zones on the rake face. The rake face is then characterized to represent all the possible cases of chip flow patterns, crater wear and chipping of the cutting edge. Side and end cutting edges are taken as datum lines for locating the wear zones. The quantification and locations of the wear zones might help the researchers and tool makers to concentrate more on the defined areas instead of the rake face in total.

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