Performance of the micro-texture self-lubricating and pulsating heat pipe self-cooling tools in dry cutting process

Abstract

The concept of self-lubricating and self-cooling tools is proposed by combining the pulsating heat pipe and surface texturing technologies. The laser beam machining and electrical discharge machining are used to prepare the micro-texture self-lubricating and pulsating heat pipe self-cooling tools. The machining performance of the prepared tools and conventional tool in dry cutting of Ti-6Al-4V alloy is assessed in terms of cutting forces, cutting temperature, chip morphology and tool wear. Results show that the cutting forces, cutting temperature, friction coefficient at the tool–chip interface, and the tool wear of the micro-texture self-lubricating and pulsating heat pipe self-cooling tool are reduced compared with that of the conventional one. Coiling chips are produced with the micro-texture self-lubricating and pulsating heat pipe self-cooling tool while long and continuous chips are formed with the conventional tool. Two mechanisms responsible are found, first of all, the advanced tool's textured grooves were filled with solid lubricants which may be released and smeared at the tool–chip interface in cutting process; on the other hand, the pulsating heat pipe embedded in the tool could accelerate heat dissipation of the cutting insert.