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Machining based friction experiments were performed using a specially designed friction measuring system. By varying the workpiece material (copper and aluminum), workpiece surface roughness (.75-3.6 micrometer), cutting tool material (coated and uncoated), operating velocity (100 and 200 m/min), and normal load (50 - 500 gm), friction coefficient results were generated at more than 250 distinct operating conditions. Using advanced microscopy and profilometer techniques, the profiles of the resultant wear tracks and chip/debris particle were obtained.