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In order to improve the performance of the cutting tool, third-generation tools with multi-layered nanocoatings on the rake face are used. During machining, the chip-tool interactions depict that although the tool wear on the rake face is located in the close proximity of the cutting edge, that is, within 800 mm, all the commercially available cutting tools have the coatings on the entire rake face. Taking into account the tribological properties required by the rake face close to the cutting edge, that is, high wear resistance and low friction, this study makes an attempt to identify, characterize and locate the actual wear zones/regions in terms of hard and soft zones in the chip contact area of tungsten carbide (WC) inserts close to the cutting edge in turning. Mamdani fuzzy inference system model was developed, trained with the sample experimental data and tested with the test data. The simulated results showed that the average error values of edge chipping (in X-and Y-directions), nose damage and crater wear (in X-and Y-directions) are about 2.37%, 3.01%, 2.86%, 2.66% and 1.89%, respectively. The fuzzy model developed in this study showed remarkable prediction of the wear zone locations and is also helpful for the researchers to decide the type of coating (hard and soft) along the specified zones for reducing the cost of production.

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Abstract. In dry turning, control over chip formation and the need for the automated machining lead to an advancement in cutting tools. Such concern towards chip breakability is necessary in reducing tool wear, tool tip temperatures and surface roughness of workpiece material. The present study proposes a new development in the traditionally available cutting tools, which acts like a chip breaker. A series of micro-grooves are machined on the rake face of Tungsten carbide (WC) cutting tools using sinker Electric Discharge Machine (EDM). These micro-grooved tools are used to dissolve long continuous chips and heat from the cutting zone in the dry machining of AISI 1040 steel. The results of micro-grooved cutting tools have shown improvement in reducing the tool tip temperatures and surface roughness compared to the conventional cutting tools. The consolidated chip flow phenomenon of plain WC tools is used to decide the location of micro-grooves on the tool rake face. A Taguchi orthogonal array is used to design an experimental layout with minimum number of repetitions in the experiments. Signal-tonoise ratios and ANOVA is used to understand and identify the significant factors & their level among the input variables on responses.From the results, it is identified that the cutting speed is the most influencing parameter for tool tip temperature at level 1 (i.e.112 m/min) and surface roughness at level 5(i.e.720 m/min).