Abstract
To study the effect of micro-texture on the cutting performance of polycrystalline cubic boron nitride (PCBN) tools, five types of micro-textures (circular pits, elliptical grooves, transverse grooves, composite grooves, and wavy grooves) were applied to the rake surface of PCBN tools by an optical fiber laser marking machine. Through a combination of three-dimensional cutting simulations and experiments, the influences of micro-texture on chip–tool contact area, cutting force, chip morphology, shear angle, and surface roughness during the cutting process were analyzed. The results indicated that the chip–tool contact area and cutting force of both non-textured and micro-textured tools increased with increasing cutting speed, while the shear angle decreased with increasing cutting speed. The chip–tool contact area and cutting force of the five types of micro-textured tools were smaller than those of the non-textured tool. The chip–tool contact area and cutting force obtained by the wavy-groove micro-textured tool were the smallest. The chip radius produced by the five types of micro-textured tools was smaller than that produced by the non-textured tool, and the chip morphology was more stable. The transverse-groove micro-textured tool had a better chip breaking effect. The chip radius generated by the elliptical-groove micro-textured tool was 0.96 cm, while that generated by the wavy-groove tool varied from 0.55 cm to 1.26 cm. The presence of a micro-texture reduced the surface roughness of the workpiece by 11.73%–56.7%. Under the same cutting conditions, the five types of micro-textured tools gave a smaller chip–tool contact area, cutting force, chip radius, and surface roughness and a larger shear angle than the non-textured tool. In addition, the elliptical-groove and wavy-groove micro-textured tools had better cutting performance.
Highlights
A micro-textured tool is one in which the rake face has a pattern of micro-pits, micro-grooves, or other micro-structures.1 Many studies have shown that micro-textured tools can improve cutting performance and extend tool life.2–6 Among the various geometrical parameters and distribution characteristics of such tools, it has been found that the type of texture is the main factor affecting cutting performance.Zhang et al.7 used micro-textured tools with linear grooves, sinusoidal grooves, or rhombic grooves to dry-cut Ti–6Al–4V alloy, and their results indicated that the greatest reductions in cutting force and tool wear and the best chip morphology were achieved with linear-groove micro-textured tools
finite element analysis (FEA) simulations and cutting experiments are carried out to study the influences of different micro-texture shapes on chip–tool contact area, cutting force, chip morphology, shear angle, and surface roughness of a polycrystalline cubic boron nitride (PCBN) tool in dry cutting of Cr12MoV
Awτc, sin β where τc is the frictional shear strength and β is the friction angle. It can be seen from Eq (6) that τc and β remain basically unchanged, and the total cutting force is proportional to the real chip–tool contact area
Summary
A micro-textured tool is one in which the rake face has a pattern of micro-pits, micro-grooves, or other micro-structures. Many studies have shown that micro-textured tools can improve cutting performance and extend tool life. Among the various geometrical parameters and distribution characteristics of such tools, it has been found that the type of texture is the main factor affecting cutting performance. Yang et al. compared the machining performances of tools with four types of micro-textures (pits, longitudinal grooves, transverse grooves, and cross grooves) in combination with friction experiments They found that the presence of a micro-texture changed the stress distribution of the workpiece and improved the wear resistance of the tool. Yu et al. carried out a high-speed cutting experiment on SUS304 stainless steel using cemented carbide micro-textured tools with pit or groove micro-textures. The results of cutting experiments with these tools showed that a groove-type microtexture with appropriate parameters could effectively reduce the cutting force and friction coefficient. FEA simulations and cutting experiments are carried out to study the influences of different micro-texture shapes on chip–tool contact area, cutting force, chip morphology, shear angle, and surface roughness of a PCBN tool in dry cutting of Cr12MoV
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