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Influence of Cutting-Edge Micro-Geometry on Material Separation and Minimum Cutting Thickness in the Turning of 304 Stainless Steel.

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Title: Influence of Cutting-Edge Micro-Geometry on Material Separation and Minimum Cutting Thickness in the Turning of 304 Stainless Steel.
Authors: Zou, Zichuan1 (AUTHOR) zichuan@gznu.edu.cn, Xin, Yang1 (AUTHOR), Ma, Chengsong1 (AUTHOR)
Source: Materials (1996-1944). Feb2026, Vol. 19 Issue 3, p591. 31p.
Subjects: Microstructure, Dislocation density, Austenitic stainless steel, Shearing force, Machining
Abstract: The micro-geometry of the cutting edge plays a crucial role in material flow ahead of the cutting edge and chip formation, primarily influencing chip formation mechanisms and the minimum cutting thickness. In the context of turning 304 stainless steel, however, existing research still lacks a unified quantitative framework linking "cutting edge micro-geometry—material separation behavior (separation point/minimum uncut chip thickness)—microstructural evolution of the machined surface." This gap hampers mechanistic optimization design aimed at enhancing machining quality. This study examines the turning of 304 stainless steel by integrating analytical modeling, finite element simulation, and experimental validation to develop a predictive model for minimum cutting thickness. It analyzes the effects of tool nose radius and asymmetric edge morphology, and a microstructure evolution prediction subroutine is developed based on dislocation density theory. The results indicate that the minimum cutting thickness exhibits a positive correlation with the tool nose radius, and their ratio remains stable within the range of 0.25 to 0.30. Under asymmetric edge conditions, the minimum cutting thickness initially increases and then decreases as the K-factor varies. The developed subroutine, based on the dislocation density model, enables accurate prediction of dislocation density, grain size, and microhardness in the machined surface layer. Among the factors considered, the tool nose radius demonstrates the most pronounced influence on microstructure evolution. This research provides theoretical support and a technical reference for optimizing cutting-edge design and enhancing the machining quality of 304 stainless steel. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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Items – Name: Title
  Label: Title
  Group: Ti
  Data: Influence of Cutting-Edge Micro-Geometry on Material Separation and Minimum Cutting Thickness in the Turning of 304 Stainless Steel.
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  Label: Authors
  Group: Au
  Data: <searchLink fieldCode="AR" term="%22Zou%2C+Zichuan%22">Zou, Zichuan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> zichuan@gznu.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Xin%2C+Yang%22">Xin, Yang</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ma%2C+Chengsong%22">Ma, Chengsong</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Feb2026, Vol. 19 Issue 3, p591. 31p.
– Name: Subject
  Label: Subjects
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  Data: <searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Dislocation+density%22">Dislocation density</searchLink><br /><searchLink fieldCode="DE" term="%22Austenitic+stainless+steel%22">Austenitic stainless steel</searchLink><br /><searchLink fieldCode="DE" term="%22Shearing+force%22">Shearing force</searchLink><br /><searchLink fieldCode="DE" term="%22Machining%22">Machining</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: The micro-geometry of the cutting edge plays a crucial role in material flow ahead of the cutting edge and chip formation, primarily influencing chip formation mechanisms and the minimum cutting thickness. In the context of turning 304 stainless steel, however, existing research still lacks a unified quantitative framework linking "cutting edge micro-geometry—material separation behavior (separation point/minimum uncut chip thickness)—microstructural evolution of the machined surface." This gap hampers mechanistic optimization design aimed at enhancing machining quality. This study examines the turning of 304 stainless steel by integrating analytical modeling, finite element simulation, and experimental validation to develop a predictive model for minimum cutting thickness. It analyzes the effects of tool nose radius and asymmetric edge morphology, and a microstructure evolution prediction subroutine is developed based on dislocation density theory. The results indicate that the minimum cutting thickness exhibits a positive correlation with the tool nose radius, and their ratio remains stable within the range of 0.25 to 0.30. Under asymmetric edge conditions, the minimum cutting thickness initially increases and then decreases as the K-factor varies. The developed subroutine, based on the dislocation density model, enables accurate prediction of dislocation density, grain size, and microhardness in the machined surface layer. Among the factors considered, the tool nose radius demonstrates the most pronounced influence on microstructure evolution. This research provides theoretical support and a technical reference for optimizing cutting-edge design and enhancing the machining quality of 304 stainless steel. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19030591
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      – Code: eng
        Text: English
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        PageCount: 31
        StartPage: 591
    Subjects:
      – SubjectFull: Microstructure
        Type: general
      – SubjectFull: Dislocation density
        Type: general
      – SubjectFull: Austenitic stainless steel
        Type: general
      – SubjectFull: Shearing force
        Type: general
      – SubjectFull: Machining
        Type: general
    Titles:
      – TitleFull: Influence of Cutting-Edge Micro-Geometry on Material Separation and Minimum Cutting Thickness in the Turning of 304 Stainless Steel.
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            NameFull: Zou, Zichuan
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            NameFull: Xin, Yang
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            NameFull: Ma, Chengsong
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            – D: 01
              M: 02
              Text: Feb2026
              Type: published
              Y: 2026
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              Value: 19
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            – TitleFull: Materials (1996-1944)
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