Experimental Research of Micro-Textured Tool for Reduction in Cutting Force

Abstract

An effect of micro-textured tool on a reduction in cutting force has reported in recent years. Some researchers have discussed that the microstructures contribute to the reduction in friction force at tool-chip interface by acting as cutting fluid reservoirs. In this study, on the other hand, a reduction in cutting force achieved by using the textured tools was confirmed even under dry condition. The results of orthogonal cutting tests employing AISI 1045 steel with non-textured and textured tools indicated that the cutting force and calculated friction coefficient at the tool-chip interface definitely reduce at relatively high cutting speed. For this friction reduction effect, effective texture patterns and optimal area ratio of concave portion to total surface were empirically suggested. Moreover, from results of the tests using tools with sectionally textured surface, it was revealed that the texture only around the position in which the chip flow separates from the tool rake face is effective to reduce the cutting force. Close observation of both tool edges and formed chips under various cutting tests indicated that changes in geometry and dimensions of dead metal formed around the cutting edge is essential for the reduction in cutting force. Finally, a mechanical cutting model having an agreement with the experimental results was discussed by employing the slip-line field method.