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Hitomi, Masuda, Trigger-Zylstra-Chao and Hug treated with the flank adhesion phenomenon in machining of metals. Those reported on the flank build-up in connection with the variation of cutting resistance.The present study is characterized by a quantitative investigation of the tool-edge smear by an optical method. It is noted from the experimental study that neither surface roughness nor cutting resistance is affected by the tool-edge smear. The volume of the rake face smear reaches a maximum at a certain cutting speed or feed. A higher rake angle or a larger flank wear decreases the volume of the rake face smear, but the relief angle has a little influence on the rake face smear.

Effect of Cutting Condition on Tool-Edge Smear in Machining of Gray Iron