To determine the effects of cutting conditions on flank adhesion, nodular cast iron grade 60 was machined dry and wet with carbide cutting tools K6, cast iron cutting grade, and K4H, steel cutting grade. Decreasing the feed rate raised the critical cutting speed at which flank build-up occurred and lowered the resultant tool force. For tools with positive rake angle, the critical cutting speed was generally higher and tool forces were lower than for tools with negative rake angle. A clearance angle of 15 deg eliminated flank adhesion, as did the use of cutting fluids. Flank build-up was analyzed chemically and metallurgically. Methods to prevent flank adhesion are recommended.

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