This paper presents experimental results of microturning of oxygen free high conductivity (OFHC) copper rods using cermet inserts of 0.1mm nose radius as cutting tool. Machining was done in DT-110 Integrated multiprocess micromachine tool. Full factorial experiments were conducted with various combinations of cutting speed, feed and depth of cut. Tool wear for different
conditions were measured offline and also acoustic emission signals (AE rms) were recorded. Variations of tool wear with time and correlation betweenAE rms and tool wear were studied. Good correlation was observed betweenAE rms and tool wear. Also scanning electron microscope images of worn out inserts were analyzed to ascertain the wear mechanisms. It was found that mostly steady machining can be obtained with medium speed and feed.

Keywords: Micromachining, Microturning, Tool wear, Acoustic emission, OFHC copper