Micro-textured Tools Research Articles

Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061

Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061

Cutting performance and lubrication mechanism of microtexture tool with continuous lubrication on tool-chip interface

Cutting performance and lubrication mechanism of microtexture tool with continuous lubrication on tool-chip interface

A novel bionic micro-textured tool with the function of directional cutting-fluid transport for cutting titanium alloy

The need for high-precision titanium alloy components is rising exponentially in the biomedical engineering. However, ultra-precision cutting of titanium alloy is challenging due to the high cutting heat because of its low thermal conductivity, which results in severe tool wear and poor surface finish. Therefore, machining titanium alloys requires excellent cooling and lubricating solution. In this research, inspired by the microstructural surface of the Nepenthes' peristome, a bionic micro-texture (BMT) with the function of directional cutting-fluid transport is developed aiming to improve cooling and lubrication condition in cutting zone. The BMT is designed and fabricated by employing a femtosecond laser on the tool surface after theoretically evaluating the fluid transporting behavior of the BMT and its essential geometry parameters. From the directional fluid transport and ultra-precision cutting tests, it is found that the BMT surface offers a high directional fluid flow rate of 3.7 m/s. Moreover, the BMT tool produces lower cutting force, and generates defect-free morphology and nanoscaled roughness. Furthermore, the BMT tool results in reduced flank wear by 84% and 82% at a cumulative cutting distance of 900 m comparing with the none-texture (NT) and micro-groove-texture (MGT) tools respectively, and exhibits excellent chip adhesion resistance. Therefore, it is feasible and promising to apply the BMT tool in ultra-precision cutting of titanium alloys components.

Study on the cooling and lubrication mechanism of magnetic field-assisted Fe3O4@CNTs nanofluid in micro-textured tool cutting

To address the challenge of insufficient lubricity and thermal conductivity of conventional lubricating fluids and single type of nanofluids during cutting, a new nanofluid (Fe3O4@CNTs nanofluid) was prepared in this paper, and the coupling effect of Fe3O4@CNTs nanofluid and micro-texture on the cutting performance of TiC ceramic tools under the action of magnetic field was revealed for the first time. The micro-texture (TTC) was prepared on the rake face of the tool by laser processing technique, and the non-textured tool (TC) was used as a control group. The conventional Fe3O4 nanofluid (F-0.5) and Fe3O4@CNTs composite nanofluid (FC-0.5) and with a volume fraction of 0.5 vol% were prepared by co-precipitation method. For facilitating the penetration of the nanofluid into the tool/chip contact area, an external magnetic field was applied during machining operations. The cutting test of titanium alloy was performed, and the influence of various magnetic field strengths on the friction properties of micro-textured tool/chip interface under the lubrication condition of Fe3O4@CNTs nanofluid was studied. Simulation analysis of the flow characteristics of nanofluid in micro-texture under the action of magnetic field was performed to provide theoretical support for the subsequent results. The results of the cutting tests showed that the cutting forces and tool wear of TTC + FC-0.5 were alleviated in the presence of magnetic field, and the cutting performance was further improved with the increasing of magnetic field from 300 Gs to 1200 Gs. Under the highest magnetic field strength (1200 Gs), TTC + FC-0.5 has 36.9 % lower cutting force and 28.15 % lower surface roughness than TC + F-0.5. Additionally, the penetration and lubrication mechanisms of Fe3O4@CNTs nanofluid on micro-textured tool/chip contact interface under the influence of applied magnetic field was exposed.

Research on CFRP cutting mechanism by the micro-textured tool using macroscopic and microscopic numerical simulations

Carbon fiber reinforced plastics (CFRP) composites are the most widespread advanced composite materials. Still, machining with traditional tools quickly generates defects such as high cutting forces and severe subsurface damage, while micro-textured tools can improve CFRP machining performance. Therefore, to reveal the cutting mechanism of CFRP processing by micro-textured tools and guide the tool design, macroscopic and microscopic orthogonal cutting models were established in this study, which compared and analyzed the material removal process and the indicated topography of unidirectional CFRP with different fiber orientations (0°, 45°, 90°, and 135°) by traditional tools and micro-textured tools, and the accuracy of the models was verified with experiments. Compared with traditional tools, micro-textured tools reduce cutting forces by minimizing the tool-chip contact length to reduce friction and converting the fiber failure form from crush failure to shear failure. Meanwhile, the texture on the rake face enables cutting burrs, effectively improving the surface quality of the workpiece and suppressing the depth of subsurface damage. In addition, the influence of different texture parameters on the machining quality of the workpiece was analyzed.

Short communication: Experiment study on micro-textured tool with internal cooling

Abstract. Higher cutting force and its temperature with faster tool wear are the causes of higher production costs and lower machining efficiency. In this paper, with the help of electrical discharge machining (EDM) and laser technology, texture holes are implemented on the rake face and the principal flank face of the tool. The cutting force, friction characteristics of rake face and surface roughness of rake face are compared with the micro-textured cutting tool and the processing technology system of non-textured inner cooling hole. The results show that the coolant can be effectively sent to the interface surfaces due to the internal cooling texture cutter.

FEM and statistical-based assessment of AISI-4140 dry hard turning using micro-textured insert

AISI-4140 is a hardenable cold work tool steel widely used in metal cutting operations due to its superior strength and heat treatment capacity. During the dry hard turning of AISI-4140 steel, high cutting temperatures are generated in the tool-chip interface due to friction. Micro-textured tools are thought to improve cutting performances in dry hard turning. The motivation is that the more reducing the chip-tool interface area, the more decreasing the friction there. Therefore, the micro-textured tools can be helpful in all metal cutting applications. This study compared the effects of micro-grooved textures at different sections on either coated or uncoated inserts according to the cutting forces and interface temperatures using FEM and Grey Relation Analysis. Experimentally calibrated FEM simulations and a statistical approach have been built. Besides the general positive sense of the micro-textured tools' effects on machining performances, this study revealed a different unexpected nuance for dry hard turning of AISI-4140 with textured tools according to the design of simulations. Where textures grooved on rake face or flank face below nose radius textures, texture sections, or relationship with coatings was found to be independent for the dry hard turning of AISI-4140 in consideration of cutting temperature and resultant cutting force. It was found that the textured tools were not statistically significant contrary to expectation. The textured tools may not be the exact solution for all machining conditions.

Evaluation of micro-textured tool performance in ultrasonic elliptical vibration-assisted turning of 304 stainless steel

Evaluation of micro-textured tool performance in ultrasonic elliptical vibration-assisted turning of 304 stainless steel

Analysis of synergistic friction reduction effect on micro-textured cemented carbide surface by laser processing

The tribological properties of circular pit, square pit, ring groove micro-textured surface and smooth cemented carbide surface were analyzed by finite element simulation method. Through theoretical analysis and friction and wear test, the tribological properties of circular pits micro-textured (CPMT) cemented carbide surface under the synergistic effect of laser processing parameters and texture arrangement parameters were deeply studied, and the interaction relationship between various influencing factors was developed. Finally, the wear morphology and element distribution of the smooth surface and the CPMT cemented carbide surface were analyzed by SEM. The results show the CPMT surface has better friction performance by comparing with other types of surface micro-textures and smooth surfaces. The laser processing parameters and arrangement parameters of the CPMT are obtained by response surface optimization: laser energy with 1103.494 J/mm2, scanning speed with 991.2 mm/s, scanning times with 3, and the radial and circumferential distance of the micro-texture with 120 μm and 182 μm, respectively. This paper establishes a systematic preparation process and design theory of surface micro-texture, which provides an important theoretical basis for the further optimization research in the field of micro-textured tools.

Investigation on influence of micro-textured tool in machining of Ti-6Al-4V alloy

Investigation on influence of micro-textured tool in machining of Ti-6Al-4V alloy

The effects of micro-texture shape on serrated chip geometry in the hardened steel AISI D2 cutting process

Five micro-textures were processed on the rake face of PCBN tools: circular pits, elliptical grooves, transverse grooves, composite grooves, and wavy grooves. The effect of different micro-textures on cutting force, the cutting temperature, the micro-morphology of serrated chips, tool wear and surface roughness were investigated utilizing three-dimensional finite element simulation and cutting tests. The results indicates that micro-textured tools can lower cutting force when compared to non-textured tools, while cutting force varies significantly during the cutting process. Micro-texture can decrease the temperature in the adiabatic shear band, changes the temperature distribution of the rake face, reduce the serrated degree, and increase segmentation frequency. However, it is more prone to cracking. The wear resistance and the surface quality of machined surface of the elliptical grooves and wavy grooves micro-texture are better.

Predicting Cutting Force and Primary Shear Behavior in Micro-Textured Tools Assisted Machining of AISI 630: Numerical Modeling and Taguchi Analysis.

The cutting tool heats up during the cutting of high-performance super alloys and it negatively affects the life of the cutting tool. Improved tool life can enhance both the machinability and sustainability of the cutting process. To improve the tool life preferably cutting fluids are utilized. However, the majority of cutting fluids are non-biodegradable in nature and pose harmful threats to the environment. It has been established in the metal cutting literature that introducing microgrooves at the cutting tool rake face can significantly reduce the coefficient of friction (COF). Reduction in the COF promotes anti-adhesive behavior that improves the tool life. The current study numerically investigates the orthogonal cutting process of AISI 630 Stainless Steel using different micro grooved cutting tools. Results of the numerical simulations point to the positive influence of micro grooves on tool life. The results of the main effects found that the cutting temperature was decreased by approximately 10% and 7% with rectangular and triangular micro grooved tools, respectively. Over machining performance indicated that rectangular micro groove tools provided comparatively better performance.

Effect of magnetic field on cutting performance of micro-textured tools under Fe3O4 nanofluid lubrication condition

Laser texturing of cutting tool is a promising surface modification method for improving the machinability and form accuracy of the machined workpieces in the precision machining of difficult-to-machine material. However, the blocking of micro-textures by the cutting chips, i.e., derivative cutting, usually occurs because of the severe friction between the tool and chip, which can hinder the effectiveness of micro-textures prepared on the rake face of the cutting tool. To address this issue, an external magnetic field was superimposed on the micro-textured tools in order to promote the infiltration of magnetic nanofluid into the micro-textured tool-chip interface, and the possible mechanisms for the effect of magnetic field on the inhibition of derivative cutting caused by the micro-textures was for the first time revealed in this research. Herein, the cutting of 316 L stainless steel with the micro-textured tools was performed under the magnetic field, and the effect of different parameters of magnetic fields on the machining characteristic of micro-textured tools (TT) under Fe3O4 nanofluid (MNF) lubrication condition was investigated. The results reveal that the MNF could be effectively migrated into the micro-textured tool-chip interface in presence of the external magnetic field, and consequently the degree of derivative cutting caused by the micro-textured tools was effectively suppressed. Thus, the machining characteristic of TT tools was gradually improved with increasing the magnetic field strength from 300 to 1200 Gs. Besides, infiltration mechanism of MNF at the micro-textured tool-chip interface under different parameters of magnetic fields were discussed.

Study on optimization of texture parameters in micro-textured cutting of titanium alloy based on ABAQUS

Tools with micro-textured surfaces can successfully lessen the primary cutting surfaces and decrease tool friction. To conduct additional research on the impact of microtexture parameters (depth, width, and spacing) on the cutting of titanium alloy. In this paper, a two-dimensional finite element simulation model for titanium alloy cutting using micro-textured tools is established by using Abaqus software, based on the response surface method, the influence of different microtexture parameters on the chief cutting surfaces and the interaction of microtexture depth, microtexture width,and microtexture spacing is obtained, it is concluded that the effect of the depth of microtexture on the chief cutting surfaces is the most significant, the microtexture spacing is the second, and the microtexture width is the weakest. The optimum parameters of the microtexture tool are microtexture depth 20μm, microtexture width 30μm, and microtexture spacing 80μm. The chief cutting surfaces is 208.26 N.

Improving the Performance of Micro-Textured Cutting Tools in Dry Milling of Ti-6Al-4V Alloys.

Micro-textured tools were fabricated by making textures on rake faces and filling them with molybdenum disulfide. Dry milling of Ti-6Al-4V alloys was carried out with the micro-textured tools and conventional tools for comparison. Results showed that micro-textured tools can reduce the resultant cutting forces, cutting temperatures, and power consumption by approximately 15%, 10%, and 5%, respectively. Meanwhile, the developed tools can improve tool lives by approximately 20–25%. The radial width of cut, the cutting speed, and the axial depth of cut all had statistical and physical effects on the energy consumption per unit of volume in dry milling of Ti-6Al-4V alloys, while the feed per tooth seemed to have no significant effect. The mechanism for improved performance of micro-textured tools can be mainly interpreted as their self-lubricating function.

Machining of hard materials using textured tool with minimum quantity nano-green cutting fluid

Metal cutting causes severe friction and heat generation in the machining zone. Previously, petroleum-based cutting fluids were applied for reducing friction and machining temperature at the machining zone. Nowadays, nano-cutting fluids are preferred owing to their higher thermal conductivity and better lubricating ability. However, during machining of hard materials (hardness, ≥50 HRC), the effectiveness of these nano-cutting fluids is limited, as they rarely reach to the cutting edge of cutting tool because of high normal stresses. In this regard, the combination of rake face micro-textured cutting tool with indigenously synthesized nano-green cutting fluids under in-house developed minimum quantity cutting fluid (MQCF) environment is accomplished for hard machining experiments. For comparison, hard machining experiments are also performed under dry machining, green cutting fluid and nano-green cutting fluid (NGCF) with untextured cutting tools. Detailed analysis shows significant improvement in hard machining performance using combination of micro-textured tools with NGCF corresponding to forces, chip-tool interface friction, workpiece surface roughness and chip morphology. It is attributed to better infiltration of NGCF in-between chip-tool interface by virtue of micro-textures present on the cutting tool rake face. Further, the proposed analytical model captures the effect of textures on the tool surface in the same way as reduced contact tools. It is in a good agreement with corresponding experimental cutting forces.

Chip formation and the interaction of mesoscopic geometric features of cutter

Most of the researches on the properties of micro-textured tools are based on an orthogonal test, while the interaction between micro-textured parameters is ignored. Therefore, this thesis is based on an interaction test to study the cutting performance of cutting tools. According to the chip morphology obtained from the interactive test, the micro texture diameter of 60 μm is obtained when the cutting is stable. It was also found that the synergistic effect of multiple mesoscopic geometric features had a significant influence on cutting performance. By analysis, we found the optimized parameters for the milling tool were D = 60 μm, l = 100 μm, l1 = 150 μm, r = 60 μm. Furthermore, prediction models of the cutting performance were established by univariate linear regression and the validity of these models was verified. Thus, this thesis provides a reference for improving the performance of cutting tools and for achieving efficient and high-quality machining of titanium alloys.

Cutting performance of micro-textured PCBN tool

To study the effect of micro-texture on the cutting performance of polycrystalline cubic boron nitride (PCBN) tools, five types of micro-textures (circular pits, elliptical grooves, transverse grooves, composite grooves, and wavy grooves) were applied to the rake surface of PCBN tools by an optical fiber laser marking machine. Through a combination of three-dimensional cutting simulations and experiments, the influences of micro-texture on chip–tool contact area, cutting force, chip morphology, shear angle, and surface roughness during the cutting process were analyzed. The results indicated that the chip–tool contact area and cutting force of both non-textured and micro-textured tools increased with increasing cutting speed, while the shear angle decreased with increasing cutting speed. The chip–tool contact area and cutting force of the five types of micro-textured tools were smaller than those of the non-textured tool. The chip–tool contact area and cutting force obtained by the wavy-groove micro-textured tool were the smallest. The chip radius produced by the five types of micro-textured tools was smaller than that produced by the non-textured tool, and the chip morphology was more stable. The transverse-groove micro-textured tool had a better chip breaking effect. The chip radius generated by the elliptical-groove micro-textured tool was 0.96 cm, while that generated by the wavy-groove tool varied from 0.55 cm to 1.26 cm. The presence of a micro-texture reduced the surface roughness of the workpiece by 11.73%–56.7%. Under the same cutting conditions, the five types of micro-textured tools gave a smaller chip–tool contact area, cutting force, chip radius, and surface roughness and a larger shear angle than the non-textured tool. In addition, the elliptical-groove and wavy-groove micro-textured tools had better cutting performance.

Preparation and cutting performance of nano-scaled Al2O3-coated micro-textured cutting tool prepared by atomic layer deposition

Abstract Al2O3 nano-scaled coating was prepared on micro-textured YT5 cemented carbide cutting tools by atomic layer deposition ALD. The effect of Al2O3 nano-scaled coating, with and without combined action of texture, on the cutting performance was studied by orthogonal cutting test. The results were compared with micro-textured cutting tool and YT5 cutting tool. They show that the micro-texture and nano-scaled Al2O3 coated on the micro-texture both can reduce the cutting force and friction coefficient of the tool, and the tools with nano-scaled Al2O3 coated on the micro-texture are more efficient. Furthermore, the friction coefficient of the 100 nm Al2O3-coated micro-texture tool is relatively low. When the distance of the micro-pits is 0.15 mm, the friction coefficient is lowest among the four kinds of pit textured nanometer coating tools. The friction coefficient is the lowest when the direction of the groove in strip textured nanometer coating tool is perpendicular to the main cutting edge. The main mechanism of the nanometer Al2O3 on the micro-textured tool to reduction in cutting force and the friction coefficient is discussed. These results show that the developed tools effectively decrease the cutting force and friction coefficient of tool–chip interface.

Assessment of Tool Wear and Surface Integrity in Ductile Cutting Using a Developed Tool

Machined parts of aluminum alloys are used in a wide range of engineering applications, such as automobile parts. Many types of tool wear may occur during machining of these alloys, which reduces tool life. Therefore, it is beneficial to undertake comprehensive studies to improve tool life (reduce tool wear) in machining aluminum alloys. In the present study, the micro-textured cutting tool's performance is compared to the non-textured tool with chip breaker (and without chip breaker) when used cutting fluid under different cooling-lubrication methods. A literature review denoted that no experimental work is available for a comparison study between texture and chip breaker performance. Scanning electron microscope (SEM) images and energy-dispersive X-ray spectroscopy (EDX) were utilized to analyze the workpiece's surface. Although many scholars have stated that the chip breaker has a good effect on cutting performance, this research showed that the chip breaker has no positive effect on reducing tool wear in aluminum machining. Nonetheless, the SEM images denote a maximum of 30% and 36% improvement in surface quality and tool life, respectively, a considerable decrease in adhesion, abrasion, and breakage wear, and a drastic reduction in the density of defective regions in the workpiece surface when the optimum micro-textured tool was used.