Abstract
Broaching is widely used in the aerospace field owing to its high efficiency and heavy load. However, heavy-load cutting causes intense squeezing and friction in the tool-chip contact area, resulting in a lack of lubrication. Therefore, three textures (i.e., micro-pit, stripe, mesh) are prepared on the rake face of broaching tool with a laser processing technique to improve cutting performance. Afterward, textures are covered with copper using the reciprocating rotational friction to enhance the wettability and heat dissipation capacity of the broaching tool. Experiments approve that striped textures covered with copper reduce the cutting force by 14.6% and the cutting temperature decreases from 90.13 to 76.9 ℃, compared with non-textured cutting teeth. Obtained results indicate that the wettability of cutting fluid on the tool surface is significantly improved due to the capillary force of micro-pores generated by the copper covering, especially in the direction to the cutting edge. Furthermore, the copper debris absorbs heat quickly in the cutting areas and is subsequently taken away by chips and cutting fluids, thereby reducing the cutting temperature.
Highlights
Arrazola et al (2020) have reported that broaching tool has multiple rows of teeth for roughing, semi-finishing, and finishing, respectively, and is frequently used in mass production due to its high efficiency
Zhang et al (2011) have proved that because of the heavy load, strong friction and extrusion occur between the tool and the workpiece during the cutting process, reducing the tool’s service life, surface quality and machining accuracy of the workpiece
Ge et al (2019) fabricated textures in different groove widths on the rake face of the turning tool by femtosecond laser. They revealed that textures enhanced the penetration of cutting fluid, improved the lubrication of the tool-chip interface, and significantly reduced the cutting force compared to non-textured tools
Summary
Arrazola et al (2020) have reported that broaching tool has multiple rows of teeth for roughing, semi-finishing, and finishing, respectively, and is frequently used in mass production due to its high efficiency. Ge et al (2019) fabricated textures in different groove widths on the rake face of the turning tool by femtosecond laser They revealed that textures enhanced the penetration of cutting fluid, improved the lubrication of the tool-chip interface, and significantly reduced the cutting force compared to non-textured tools. Mashinini et al (2020) applied the wire spark erosion machining technology to fabricate textures on the rake face of the turning tool Both results showed that the textured tool effectively reduces the cutting force, temperature, and wear. Deng et al (2012) processed three different types of textures on the rake face of WC/Co cemented carbide tools, and the groove was filled with MoS2 solid lubricants They reported that the elliptical textured tools with MoS2 have outstanding self-lubricating properties through the dry cutting test of carbon steel.
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