This research work is concentrated on a detailed analysis of the role of tool-chip contact length in the cutting process. The work has been carried out as a series of tests in order to map different factors affecting the contact length as well as factors affected by the contact length when turning conventional construction steel using carbide tools (coated and uncoated). The tests have been performed using production cutting data for three-dimensional cutting. The work includes mapping of the relationship between contact length and cutting data, work material, coating material, cutting forces, flank wear, and tool temperature. The results from the above-mentioned relationships have been used in a graphical solution, according to the Rowe and Spick model, to clarify the effect of tool-chip contact length, cutting data and coating material on the rate of the total work done through its effect on the shear-plane angle.
