Lubricant transportation mechanism and wear resistance of different arrangement textured turning tools

Abstract

The textured tools present improved cutting efficiency and tool wear and be applied to the turning of difficult-to-cut materials. The unique transport performance of lubricant in the second deformation zone of the cutting zone is one of the advantages for sustainable manufacturing, which is significantly affect by micro-textured arrangement. However, the direct observation of infiltration phenomenon is rarely studied. The anti-friction performance and machinability of cast iron MQL turning with micro-textured tool is needed. This paper undertook theoretical analysis, infiltration and turning experiments of six typical arrangements of textured tools to provide a comprehensive understanding of the transportation and antifriction mechanism. Firstly, a theoretical analysis of the transport mechanism of different textured tools was conducted, revealing variations in surface wetting speeds due to the capillary action mechanism during the transport process. Secondly, confirmation was obtained through the capture of real-time infiltration processes using a high-speed camera, showing that, compared to non-textured tools, the infiltration speed noticeably slowed. This increased lubricant storage time and enhanced lubrication performance. Lastly, it was revealed through turning performance experiments that the 45° textured tools demonstrated outstanding performance in enhancing material removal efficiency and reducing heat accumulation. The wear resistance was superior, with reductions of 15.3%, 16.7%, and 25.4% in cutting forces in the three directions compared to non-textured tools, and a 12.2% decrease in cutting heat. Thus, validating the correctness of the capillary action theoretical analysis lays the foundation for the future application of textured tools in aerospace, automotive manufacturing, mold industry, and other fields.