Performance study of dimple and channel textured tools during turning of Inconel-718

Abstract

Alterations in cutting tool surfaces are being looked at as futuristic developments in cutting tool technology. Tool surface texturing by subtractive as well as an additive way can contribute to the tool performance and productivity improvement. The tool textures can be in the range of nano to micro-level. They help to reduce friction, manage the heat-induced during machining and facilitate chip removal. For textured surfaces, small cavities or dimples uniformly distributed over the sliding surface have been found to have the best tribological effect. In this study, two different micro-texture patterns i.e., micro-dimple and micro-channel were made on the rake-face close to the main cutting edge of the carbide tool insert. Ultra-short pulsed (nanosecond) fiber laser has been used for texturing. An array of texture patterns with 80 µm width/diameter and 70 µm depth has been engraved on the uncoated tungsten carbide tool. The textured inserts have been used for machining trials at 30 m/min to 100 m/min for Inconel 718 to compare the relative performance of the textures in terms of three components of cutting force and machined surface roughness. The experimental observations showed higher components of cutting force for channel textured tools in comparison to dimple textured tools. However, a better surface finish has been observed with channel textured tools. Cutting forces has been observed varying significantly with cutting speed in the case of dimple textured tools. Radial forces were observed higher in magnitude followed by tangential cutting force and feed force for both the textured tools. This study suggests having further studies considering the effect of different texture patterns on the cutting forces, surface roughness, and tool life while turning Inconel 718.