Effect of small nose radius on tool performance Considering turning with a single-point tool, what is a typical consequence of using a very small nose radius at the cutting tip?

Introduction / Context:
Nose radius is a key geometry parameter on turning tools. It influences surface finish, edge strength, and cutting forces. Choosing too small or too large a radius has trade-offs that directly affect tool life and surface quality.

Given Data / Assumptions:

• Standard turning on steels with carbide or HSS tools.
• Feeds in common finishing ranges.
• No special edge honing beyond typical prep.

Concept / Approach:
A very small nose radius creates a sharp point with limited support behind the cutting edge. This increases stress concentration at the tip and makes the edge susceptible to micro-chipping, especially under intermittent cutting or hard inclusions. The result is accelerated wear and reduced tool life. Moderate radii distribute cutting load and improve finish up to a limit; excessively large radii can induce chatter at light feeds.

Step-by-Step Solution:

Verification / Alternative check:
Tooling handbooks recommend selecting nose radius proportional to feed (e.g., radius roughly 1/3 to 1/2 of feed per rev) to balance finish and edge strength, avoiding extremely small radii.

Why Other Options Are Wrong:
Increases tool life: opposite of typical outcome with very small radii.Decreases life only due to rubbing: rubbing is less relevant; the issue is edge strength.Eliminates stress and heat: incorrect; stress concentration increases.Improves finish at all feeds: too small a radius can leave torn surfaces at higher feeds.

Common Pitfalls:
Assuming smallest radius always gives sharpness and best finish; without support, edge fractures and finish degrades. Match radius to feed and rigidity.

Final Answer:

Produces chipping and decreases tool life