Chip segmentation and the tool forces involved during cutting of hardened steel are discussed. AISI 4340 steel was machined on an engine lathe to study chip morphology, tool forces, and the surface generated. It was found that chip segmentation occurs when the hardness of the steel exceeds a certain value, and that the tool forces associated with chip segmentation are very high. A transformed layer of untempered martensite and retained austenite was produced when the cutting conditions were severe.
MST/469
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