Limitations are associated with each type of tooling, and manufacturers continuously strive to limit the tool geometries' drawbacks. Recently, a modified tool geometry, called the Xcel insert, has been fabricated by combining the benefits of various tooling. Two Xcel insert variations are introduced for chamfer provision, one for 1-mm (A1) and the other for 2-mm (A2) depths of cut, for turning hardened D2 steel. The output responses were measured to determine tool life, wear mechanisms, material removal, power consumption, workpiece surface roughness, microhardness, and microstructure and compared those of recently published works on AISI D2 steel turning. The Xcel inserts have outperformed conventional and wiper inserts concerning material removal, and the workpiece surface roughness (Ra = 0.38 μm) is also comparable or better. The softening of workpiece material (10–20%) was noticed adjacent to the machined sub-surface at a depth of 150 μm without any white-layer formation or microstructural damage. One-step sustainable machining approach, where feed rate and depth of cut are corresponding to roughing applications, while the workpiece roughness is comparable to that of finished machining, is feasible with Xcel inserts. That is comparable or better results could be achieved with fewer resources, including less cycle time. Furthermore, due to lower energy consumption, low tool wear, and better surface integrity, the use of A1 inserts is recommended over A2 inserts.

每种类型的工具都有局限性，制造商不断努力限制工具几何形状的缺点。最近，通过结合各种工具的优势，制造出了一种经过改进的工具几何结构，称为Xcel刀片。引入了两种Xcel刀片变种以进行倒角加工，一种用于切削深度为1毫米（A1），另一种为2毫米（A2）的切削深度，用于车削淬硬的D2钢。测量了输出响应，以确定刀具寿命，磨损机理，材料去除，功耗，工件表面粗糙度，显微硬度和显微组织，并比较了最近发表的关于AISI D2钢车削的作品。在材料去除方面，Xcel刀片的性能优于传统刀片和擦拭刀片，并且工件表面粗糙度（Ra = 0.38μm）也相当或更好。观察到工件材料的软化程度（10–20％）靠近加工的子表面，深度为150μm，没有任何白层形成或微结构破坏。Xcel刀片可实现一步式可持续加工方法，其中进给速度和切削深度与粗加工应用相对应，而工件粗糙度可与精加工媲美。这是可比的，或者用更少的资源（包括更少的周期时间）可以达到更好的结果。此外，由于较低的能耗，较低的工具磨损和更好的表面完整性，建议使用A1刀片而不是A2刀片。Xcel刀片是可行的，其中进给速度和切削深度与粗加工应用相对应，而工件粗糙度可与精加工媲美。这是可比的，或者用更少的资源（包括更少的周期时间）可以达到更好的结果。此外，由于较低的能耗，较低的工具磨损和更好的表面完整性，建议使用A1刀片而不是A2刀片。Xcel刀片是可行的，其中进给速度和切削深度与粗加工应用相对应，而工件粗糙度可与精加工媲美。这是可比的，或者用更少的资源（包括更少的周期时间）可以达到更好的结果。此外，由于较低的能耗，较低的工具磨损和更好的表面完整性，建议使用A1刀片而不是A2刀片。