Modeling and Analysis of Textured Surfaces on a Single Point Cutting Tool

Abstract

While performing any machining operation like turning or facing with the help of single point cutting tool various factors affect the machining operation. For any machining operation, the operation should always be completed in minimum possible time and should possess excellent surface finish at optimal cost. Therefore, to achieve these properties study on single point cutting tool is to be made and some modifications of the tool with proper analysis is to be done. This modification involves providing micro textures on the surface of the rake face of carbide inserts. The primary purpose is to note that how the microgroove textured tools perform while machining and to compare this performance with non-textured cutting tools. Groove width, groove depth and width to depth ratio are the parameters that are examined. The texture provided will increase its efficiency and reduce the friction caused due to the tool chip interface, increasing tool life. A proper flow of lubrication over the tool due to texture will ensure less friction between the tool and the chip generated. To check whether the provision of texture would involve undesired stress on the tool, simulation is carried out in ANSYS. For experimental analysis different combinations of groove width and groove depth are textured on the carbide tool and forces are calculated by mounting strain gauges on the tool holder. Calculations of forces involve proper calibration of tool holder on Universal Testing Machine. Forces involved are namely cutting force, feed force and neutral force, are calculated using Wheatstone bridge connected across strain gauges mounted on the tool holder. It is found that tools with micro textures generate lower cutting force and feed force.