Experimental Study on Tool Performance in the Machining of AISI 4130 Alloy Steel with Variations in Tool Angle and Cutting Parameters

The high hardness and toughness of AISI 4130 alloy present significant challenges during machining, including excessive cutting forces, rapid tool wear, and poor surface finish control. To address these issues, this study combines numerical simulation with turning experiments to systematically investigate the effects of tool geometry and cutting parameters on cutting force, temperature, and surface roughness. Through Deform-3D finite element modeling, one-factor, and orthogonal simulation tests, it was found that the optimal tool geometric combination (λs = 2°, κr = 99°, γ0 = 5°) reduces the cutting forces by 21.86% as compared to the baseline parameters. Experimental validation showed that the agreement between simulated and measured cutting forces was 86.73%–87.8%, with simulated values being 10%–13.27% higher due to idealized boundary conditions. Surface morphological analysis by Bruker Contour Elite K shows that the surface roughness of the workpiece decreases with an increasing cutting speed and increases with an increasing feed rate and depth of cut. The above studies provide a certain research basis for optimizing the tool angle and improving the cutting efficiency.