Nose Radius (r) = 0.1 to 0.2 mm:

• Sharp tool mitigates chatter by alleviating cross-coupling effect
• Reduced tool strength due to sharp nose is compensated by thicker insert body
• Increased surface roughness controlled by MC effect, low Ce and moderate Cs

Side Cutting Edge Angle (Cs) = 20 °

• Chatter control by nullifying interference effect and controlling regenerative effect
• Improved tool life owing to cutting forces being distributed onto a larger area
• Improved surface quality through reduced chatter and vibration.

End Cutting Edge Angle (Ce) = 10°

• Back forces kept in check to avoid chatter
• Sufficient clearance between tool and workpiece reduces tool wear
• Low Ce is congenial for a better machined surface

Surface Texturing

• Reduced cutting forces and cutting temperature due to smaller tool-chip contact contributes to chatter control
• Improved tool life due to reduced friction and improved heat dissipation by solid lubricant
• Negative impact on surface quality compensated by proposed tool geometry features of Cs and Ce + MC effect

Mechanochemical Effect

• Sinuous flow, a material deformation mode, generates large forces and thick chips.
• Prestraining the annealed work material can reduce strain and cutting forces by 70%.
• Applying a Dykem ink layer can suppress sinuous flow, reducing cutting forces and improving surface quality.

Advantages

• A cutter with lower cutting forces and energy consumption.
• Alleviate parasitic mechanisms like chatter, tool wear, and plowing.
• Having sustainability in manufacturing.
• Novel Turning Cutter Tool Design.
• Features smaller nose radius, designated cutting edge angles, and surface texture on insert rake face.
• Incorporates geometry features and mechanochemical effect to reduce cutting forces and energy.
• Improved surface quality, increases tool life, and increases throughput.
• Suitable for multipoint milling and precision cutters, facilitating sustainable machining operations.