An experimental analysis has been carried out as serial tests with the aim of making a thorough study of the relationship between tool-chip contact length, tool life (flank wear) and tool temperature. A series of tools with restricted contact lengths (0.2 - 1.3 mm) have been used to machine carbon steel using different cutting data. The test result shows that reducing the contact length from the natural length will reduce the flank wear, but if the contact length is too heavily restricted, tool wear will increase rapidly. The test result also shows that a reduction of the contact length from its natural size to one smaller than the adhesion zone (zonel) leads to a displacement of the point of maximum temperature towards the cutting edge, which results in fast growing flank wear and plastic deformation of the cutting edge. The results are used to determine why the capacity of the same tools differs with different restricted contact lengths.
