The machining of difficult-to-machine materials, such as hardened steel, titanium alloys, inconel, and stainless steel, is usually associated with low productivity, high cost, poor surface quality, and short tool life. Therefore, improving the machinability of difficult-to-machine materials is essential. In this study, the development of a built-up layer (BUL) under certain cutting conditions was promoted to protect the tool surface and extend the tool life when machining hardened steel S45C (H-S45C) with an uncoated WC-Co tool. The dimensions, microstructure, and chemical compositions distributions of the BUL were accurately measured. The tool wear and roughness of the machined surface were also determined to evaluate the usefulness of the BUL. From the results, it was shown that the BUL, composed of an elongated microstructure of H-S45C, acts as a protecting layer on the tool surface, decreasing the tool wear and extending the tool life; Further, the relationship between the formation of the BUL and the surface roughness was also experimentally verified. It was confirmed that the BUL formed during the machining of H-S45C helped maintain the quality of the finished surface, and the adhesion on the nose helped decrease the variations in the surface roughness of the finished surface.
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