Adhesive wear in machining is caused by adhering through micro welding of workmaterial on the cutting tool, this may lead to the formation of built-up edge andbuilt-up layer. This is known as secondary adhesion, the wear mechanism mayalso lead to pieces of the tool coating being ripped of and following the chip, which is known as primary adhesion. The wear mechanism most often results in the deterioration of the cutting tool. The aim of this experimental study is toenable examination of the phenomena. The objective is to bring forth experimental equipment and measuring methods and procedures that can be used for this purpose. A method for examining the phenomena in turning was achieved using manual lathe and cemented carbide inserts of the type Sandvik “CNMG 12 04 08 -XM4325”, with a coating consisting of CVD Ti(C,N)+Al2O3+TiN. The inserts were marked at the rake face for reference in examination. The work material used wasthe quenched and tempered steel EN-34CrNiMo 6 and the austenitic stainless steel EN-1,4436. The cutting speed at which the adhesive wear is prominent in machining of these work materials, was determined by radial turning of the material ends. In order to remove the adhered work material, the inserts where cleaned with hydrochloric acid and ultrasonic washing. The inserts were examined with a scanning electron microscope (SEM) prior to and after cleaning. The results from the SEM examination show that the inserts have a spongy looking texture on the surface with craters and holes. By comparison of the surfaces between different engagement time with work the material, it was found that because of adhesive wear, the texture of the surface slowly changes. The changes consists of enlarging of existing craters and new ones being created. This result meant that the examination with SEM was deemed a good method for examining the phenomena. The results also showed that the texture of the surface could also be affected by the ultrasonic washing, which meant that this method of cleaning is not recommended. The recommendation is instead to bathe the inserts in the hydrochloric acid without the ultrasonic wash for 30 minutes.

Adhesive wear occurs when small surfaces of the cutting tool due to friction are micro-welded to the chips and removed from the tool surface. A hypothesis as to whywelding occurs is that an electric potential field arises which initiates a chemical reaction and then welding of the work material and the tool takes place in the cuttingzone. The electric potential field results in a fluttering magnetic field, which in turngenerates electromagnetic issues. The waves should be around and above 1 MHz.The aim of this work is thus to investigate the presence of electromagnetic wavesfrom the cutting zone. The purpose is to compare sound and electromagnetic wavesduring the adhesive process. Previous research shows that the adhesive mechanism is a transient vibration thatmanifests itself as a cluster of waves with a stochastic duration, including a feedbacksystem restricted by the plastic deformation within the chip. Furthermore, the cutting speed is the most important cutting parameter in tool wear and the main wearmechanism at cutting speeds around 200 m/min is the adhesive wear. Several studies showed the emission of electromagnetic waves during plastic deformation ofmetals during tensile test. Frequency ranges for radiations are between 1 and 1000MHz. To investigate the hypothesis, axial turning was performed with a cutting speed190–200 (m/min) and one steel grade, SS2541 was used as a work material. Thedepth of cut and feed were set to 1 mm and 0,196 mm/rev. Detection and measurement of electromagnetic waves was performed with a spectrum analyzerMT8221B with four different signal receivers. A reference measurement was madewhen the turning machine was on without the workpiece being machined and then ameasurement was made during the turning process. The results of measurementsshowed a source of electromagnetic radiation within the frequency range 0–5 MHz.This result was achieved with copper plate as an antenna. To find out how signalsfrom acoustic emission and electromagnetic waves develop during the adhesive wearprocess, sound measurements were performed with microphones during the turningprocess. Results of sound measurement showed that the frequency at which adhesivewear occurs decreases and the amplitude increases as the insert wears. To be able toanalyze how electromagnetic radiation develops with the wear process, measurements must be performed in a shielded space from ambient disturbances, as in aworkshop there are many sources of noise that can affect the accuracy of the measurement. An antenna can be designed so that the measurement can take place asclose to the cutting zone as possible.