The insert groove geometry is an important part of turning tool design. In this article, a systematic design approach is presented for the chip breaker design in turning. The chip breaking ability of various groove geometry of a turning insert is investigated. The ratio of chip thickness to chip curl radius is taken as the index of chip breaking performance. Taguchi method is applied to analyze the contribution to chip breaking performance of each geometric parameter. Response surface methodology is then used to construct a predictive model evaluating the effect of turning conditions and groove geometry on chip breaking performance. The result of this study shows that the feed rate significantly affects chip breaking performance, and that insert with larger land angle, higher back wall and smaller groove is more effective in chip breaking. Among the parameters of the insert groove, the width of the groove has the greatest contribution to chip breaking than the others. The simulation results and predictions are validated by turning experiments.
