Orthogonal metal cutting allows the collection of force data in the laboratory in an analytical manner not practical during industrial applications. Orthogonal tube turning (OTT) allows the collection of force data at much higher speeds than the original methods used by Ernst and Merchant. An orthogonal tube turning apparatus was constructed and validated in order to study the effects of rake angle, uncut chip thickness and cutting environments on the tool forces and the wear of the tool face itself. Although there have been many studies which characterized the forces and the surface finish of the part machined, along with some version of tool life, this study is unique in that the wear of the tool face itself is characterized in a detailed analysis of variance (ANOVA) study. A widely utilized commercial water based product performed less well than either nitrogen gas or cold shop compressed air. Surface roughness of the tool was used to parameterize tool surface finish for cutting each factor level combination of the experiment.

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