Influence of texture parameters of the bio-inspired crescent textured tool on machining performance of martensitic stainless steel

Abstract

Recently surface textured tools have gained much attention as sustainable machining techniques in enhancing the tribological characteristics at tool and workpiece interfaces. However, minimal research is conducted to inspect the influence of bio-inspired textured tool cutting performances. Therefore in the current investigation, the influence of variation in the rake and flank faced bio-inspired crescent textured tool parameters such as radius, edge distance, depth, and center distance on the cutting performance of difficult to machine martensitic AISI 420 steel has been examined. The turning operation has been conducted at a constant depth ( a p ) = 0.3 mm, cutting speed ( v c ) = 315 m/min and feed ( f z ) = 0.14 mm/rev. The bio-inspired crescent-shaped textured tool indicated a reduction in feed force, tangential force, chip-tool contact area, flank wear and chip reduction coefficient compared to the conventional tool. The built-up edges, chipping, and abrasion are common tool wear mechanisms noticed on the tool surface. It is noticed that out of different texture parameters, center distance of the crescent textured tool played a vital role in improving the machining performance with minimum feed force, tangential force, contact area, flank wear, and chip reduction coefficient of 49 N, 118 N, 7.96 E + 05 µm 2 , 103 µm and 1.695 is observed using the textured tool of center distance of 80 µm. These research findings are significant for increasing the bio-inspired textured tool applications with superior tribological characteristics. • Bio-inspired crescent textured tool performed superior compared to conventional tool. • Texture parameters plays vital role in improving machining performances. • BUE, abrasion, and chipping are common tool wear mechanisms observed. • Textured tool showed lower chip reduction coefficient.