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In this work analysis of fundamental aspects of orthogonal microcutting was carried out in terms of variables like shear angle, chip thickness, chip morphology as a function of cutting speed, depth of cut, tool rake angle and heat treatment provided to the work specimen. Analysis of results shows that the material flow pattern at low cutting speed is highly inhomogeneous, which affects segmented chip formation. As the uncut chip thickness approaches the minimum chip thickness, chips are formed by shearing of the workpiece, with some elastic deformation still occurring.At the highest depth of cut of 100 μm, shear angle is fairly dependent on the rake angle. AISI 1215 steel heat treated at 1200C, shows the lowest shear angle at all the depths of cut at 5 or 10 of rake angle. Analyses of chip segment per unit length show that, the number of segments reduces as the rake angle increases for all the four work materials that were heat treated at the various temperatures.

Experimental analysis of orthogonal micro-machined surface features and chip morphology of AISI1215 steel by using EBSD method