Micro-textured Tools Research Articles

Influence of tool micro-texturing, cooling conditions and cutting conditions on workpiece surface integrity and tool condition

Improving cutting tool life is very crucial in manufacturing industry. The quality of the finished product is equally important. Investigations are being done to identify different methods to minimize tool wear and improve surface integrity. Micro-texturing of tools is one of the possible methods to improve life of the cutting tool. This work investigates the influence of type of tool: micro-textured, untextured tool; cooling conditions: dry, flood machining; process parameters like cutting speed: low and high, feed: low and high and depth of cut: low and high on surface integrity of machined low alloy steel. Micro-textured tools showed better performance over untextured tools by decreasing the tool crater wear area, roundness error and surface roughness of the finished part. Type of tool, cutting condition, feed and depth of cut influenced roundness error the most. Cutting condition influenced crater wear and feed influenced surface roughness the most.

INVESTIGATION ON THE MACHINABILITY OF TITANIUM GRADE 23 USING TEXTURED CUTTING TOOLS WITH CHIP BREAKER

In this paper, an experimental investigation of the machinability of Titanium grade 23 has been carried out using hybrid micro-textures on the cutting tool. The different types of micro-textures have been fabricated on the rake surface as well as on the flank surface of the cutting tool. The performance of textured tools with the presence of a chip breaker has been investigated. The selected patterns were vertical grooved rake face (VT-R), diagonal grooved rake face (DT-R), vertical grooved flank face (VT-F) and hybrid textured tools namely, vertical rake and flank (V+V), diagonal rake and vertical flank (D+V). A comparative study has been carried out to acknowledge the performance of textured tools while dry turning Titanium Grade 23 alloy. The machinability has been made to acknowledge the performance of textured tools with the variation of machining time in case of dry turning operation. The machinability criteria are investigated based on cutting forces, cutting temperature and tool wear mechanisms involved while machining. The performance of the cutting tool with DT-R and VT-F micro-texture is observed to be better in comparison to others. Innovative applications of micro-textured tools are for dry green machining without any environmental hazards and proper chip-flow control.

Study on the Properties of Sinusoidal Micro-Textured Ball End Milling Cutter for Milling Titanium Alloy

To improve the cutting performance when cutting hard alloys and achieve reasonable optimization of micro-texture parameters, this paper proposes a sinusoidal micro-textured tool, with four parameters set as micro-textured spacing, period, width, and amplitude. Establish three-dimensional models of non-micro-textured and micro-textured milling tools and simulate the milling process using finite element simulation. Study the effects of milling force and milling temperature on tool performance. Prepare micro-textured milling tools for orthogonal experiments, analyse the effects of milling force and the surface roughness of a titanium alloy workpiece, and study the impact of different micro-textured parameters on milling tool performance. Obtain the parameters that have the greatest impact on milling tool performance, and then use genetic algorithm to optimize three sets of parameter combinations. Use the optimized parameters to prepare milling tools for comparative experiments, and then determine the optimal parameter combination. The research results indicate that micro-textured tools can effectively improve the milling performance of the tool, and the spacing between sinusoidal micro-textures has the greatest effect on improving the milling performance of the tool. When the period of sinusoidal micro-texture is 2.87 and the amplitude is 25.13 μm, width is 79.89 μm, and spacing is 134.54 μm, the milling performance of the tool is optimal.

Finite element investigations for chip scraping during orthogonal cutting process with micro-textured tools

Compared with the conventional tool (CT), the micro-textured tool (MTT) has the advantages of reducing cutting forces, lowering cutting temperatures and inhibiting tool wear. However, the chip scraping phenomenon generated in the cutting process has negative effects and degrades cutting performance when using the MTT with grooves perpendicular to the cutting edge. Due to the difficulty in observing and characterizing chip scraping in situ by experiments, its mechanism and influence on specific cutting forces and tool wear are not fully understood. To this end, finite element (FE) method is employed for simulating the cutting process with MTT. The simulation model is validated by comparing the predicted and measured specific cutting forces. The average prediction error of specific cutting and feed forces is 12.4 % and 18.8 %, respectively. The simulation results indicate that chip scraping mainly results from the discontinuity, non-uniformity and high contact stress state of the tool-chip interface. The minimum specific cutting force is achieved when the advantages of micro-texture and the chip scraping effects are balanced. The MTT rake face wear is subdivided into a severe and a sliding wear zone. This partition characteristic is closely associated with normal contact stress and temperature distributions. The work in this paper contributes to improving the understanding of chip scraping, optimizing micro-texture and cutting parameters, and promoting MTT applications in the manufacturing industry.

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

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.

Improving the frictional properties of the tool/chip interface of micro-textured ceramics tools by using electromagnetic-assisted nanofluids

During the machining of stainless steel by ceramics tools, the tool/chip interface is difficult to be effectively cooled and lubricated due to the poor thermal conductivity of ceramic and stainless steel materials, resulting in the high cutting temperature and severe tool wear. To enhance the penetration of nanofluid into the tool/chip interface, a novel approach of magnetic field-assisted electroosmotic was proposed. The external magnetic field was introduced during the cutting process, and the self-excited electric field generated by intense tool/workpiece interface friction was considered. The effect of electromagnetic field-assisted Fe3O4 nanofluid lubrication on the cutting performance of micro-textured tool was investigated. The results showed that Fe3O4 nanofluid (NF) can be effectively migrated to the tool/chip interface driven by the electroosmotic force, Lorentz force and pressure to alleviate the tool wear. In particular, with increasing of electromagnetic field strength, the cutting performance was significantly improved. In addition, the mechanism of NF permeation at the micro-textured tool/chip interface under the electromagnetic field was revealed by combining the finite element simulation. This work provides a new method for efficient cooling and lubrication of the tool/chip interface during the machining of difficult-to-cut materials, and the drive theory of cutting fluid penetration is also enriched.

Development of Electrochemical Microtextured Cell for Fabrication of Complex Micropattern

Introduction: This paper highlights the representative patents related to the application of maskless electrochemical micromachining (EMM) using microtextured tools and developed cells under electrolysis conditions for the generation of high-quality complex patterns, i.e., cascade micropattern on stainless steel. background: Electrochemical Microtextured Cell Method: To acquire high accuracy level, the workpiece and tools are fixtured properly in the developed microtextured cell, and a developed vertical cross-flow system is utilized for the generation of a precise cascade micropattern. An electrochemical microtextured cell is designed and developed inexpensively for the fabrication of high-quality complex micropatterns. The eco-friendly combined electrolyte of NaNO3 and NaCl is employed for precise micro texturing. Result: The consequence of predominant input factors, i.e., IEG, voltage, and flow rate, are explored on machining rate, precision, depth, and surface finish during complex micro-texturing using developed microtextured cells. The complex microtextured tool is fixtured in tool holding device in a developed microtextured cell and fabricates nineteen precise complex micropatterns. Conclusion: An effort has been made to find suitable input factors for the generation of precise complex micropatterns.

Machining performance of micro-pit and micro-groove composite textured tools in tungsten alloy turning

Tungsten alloys are widely used in aerospace because of their high-temperature resistance, corrosion resistance, high strength, and other excellent comprehensive properties. But tungsten alloys are typical hard-to-machining materials. Surface micro-textures can improve friction properties, such as preparing micro-textures on the surface of cutting tools for tungsten alloys, which is expected to enhance the cutting performance of tungsten alloys. Still, the relevant cutting laws need to be further studied. A combination texture of micro-pit and micro-groove was designed, and the micro-textured tool surface was prepared by laser machining. Compared with non-textured tools, micro-pit and micro-groove composite textured tools can effectively improve the processing quality of tungsten alloys. It happened because textures on the tool’s surfaces enhance machining performance by reducing the actual contact area between the tool and the chip and storing lubrication medium. At the same time, comparative experiments of micro-textured tools and non-textured tools were carried out. The results showed that when cutting W93NiFe alloys with textured and non-textured tools, the maximum reduction in resultant cutting forces with textured tools was 9%. The maximum reduction in surface roughness was 39.3%, the surface burr height of the tungsten alloy workpiece was lower, the number of surface grooves was lesser, and the surface was more flat. The research results are significant in achieving the efficient processing and high-quality manufacturing of tungsten alloys.

Research on Machinability of Dry Cutting 7075 Aluminum Alloy with TiN Coating Micro-Texture Turning Tool

This document suggests a cutting technique for coating the surface of micro-textured structural tools, aiming to tackle the challenges in machining aluminium alloy materials that are hard to machine and simple to soften and stain at elevated temperatures. Initially, considering the varied conditions of cutting dosage during the process caused by diverse forces, the favored parameters for cutting are; next, creating two distinct phases of the micro-texture for application on the tool’s surface, conducting cutting simulation tests with the previously mentioned ideal parameters to evaluate these micro-texture structures in enhancing tool efficiency; ultimately, the focus is on the optimal surface coating of the micro-texture tool to examine how the coating material enhances at the tool’s cutting temperature. Studies have shown that the effectiveness of concave elliptical micro-textured tools in decreasing cutting force and temperature is markedly superior to that of convex elliptical micro-textured tools; experiments revealed that applying a coating to the concave elliptical micro-textured surface of the tool markedly enhances the friction level of both the cutting tool’s front surface and the workpiece’s cutting layer in dry cutting scenarios, thereby decreasing the cutting temperature and chip damage, markedly enhancing the aluminium alloy material’s ability to heat stain the tool.

Study on milling behavior of TiAlN coated tool with variable distribution density micro-texture

Considering that after milling titanium alloy with a ball-end milling cutter, the wear degree of different areas of the rake face is different, which indicates that the tool-chip contact conditions in this area are different, and then the micro-texture action mode is different. To improve the effect of micro-texture, this paper establishes a mathematical distribution model of variable distribution density micro-texture based on the two-zone method, builds a variable distribution density micro-texture ball-end milling titanium alloy test platform, studies the influence of variable density micro-texture parameters on tool milling behavior, and optimizes the parameters based on the improved particle swarm optimization algorithm. The results show that the micro-texture with variable distribution density has a positive effect on the milling behavior of the tool. The micro-texture parameters of the stickiness area have the greatest influence on the milling behavior of the tool. A texture parameter is optimized, and the overall milling behavior of the variable density micro-texture TiAlN coated milling cutter is optimal. This study provides a theoretical basis for the design and preparation of variable distribution density micro-textured tools. Highlights Based on the two-zone method, the mathematical distribution model of the variable distribution density micro-texture of the rake face of the tool is constructed. The influence mechanism of micro-texture parameters on the milling behavior of a ball-end milling cutter is explored. The multi-objective optimization of the variable density micro-texture parameters was carried out, and the optimal parameter combination was obtained. It is verified that the variable distribution density of the micro-texture has a positive effect on the cutting performance of the tool.

Effect of Composite Bionic Micro-Texture on Cutting Performance of Tools

Dry cutting is an effective method to realize the concept of green cutting today. However, in the process of cutting bearing steel, the high temperatures and high pressures produced by the cutting tool and chip under dry friction seriously affect the machining performance of the tool. Therefore, a bionic microstructure tool based on bionics is proposed to improve the cutting performance and reduce friction by changing the size parameters of the microstructure. On the basis of finite element simulation and cutting tests, the cutting force, surface roughness, and chip shape are used to evaluate the cutting performance. It is found that composite bionic micro-textured tools have a significantly reduced cutting force compared with non-micro-textured tools; composite bionic micro-textured tools lead to a reduction in surface roughness of 10–25%; and composite bionic micro-textured tools are more prone to enhancing the curling and breaking of chips. In addition, with the increase in the microstructure area occupancy, the cutting performance of the tool was also significantly improved. Moreover, it was found that the cutting performance of the tool was improved when the area occupancy of the micro-texture on the front face of the tool was increased.

Comparative study on cutting performance of different micro-texturing milling tools for preparing the L-PBF-formed TC4 workpieces

Cutting tests were performed on L-PBF-formed TC4 workpieces using different dry-cutting tools and MQL tools. The three aspects of tool wear pattern, cutting force, and surface quality of the workpiece after machining were systematically analyzed and studied for the test results obtained. Changing the micro-texture pattern on the tool effectively reduces the cutting force during milling. With the dry-cutting process, the cutting forces generated by the bionic elliptical micro-texture tool were 44 % lower than those generated by the Original tool. Milling the TC4 surface with the bionic elliptical micro-texture tool under the MQL process produced lower cutting forces of only 8.9 N, 67 % lower than the Original tool. To a certain extent, using bionic elliptical micro-texture tools protects the integrity of the workpiece, and the service life of tool is extended.

Research on Wear of Micro-Textured Tools in Turning GH4169 during Spray Cooling

In this study, the wear resistance of micro-textured tools was explored. Micro-textured tools with different morphologies were used in turning GH4169 during spray cooling. The tool wear on the rake face of the different micro-texture morphologies was investigated through simulation and experiments. Firstly, based on the existing research on bionics, micro-textures with five different morphologies were designed on the rake face of carbide tools. A simulation model of cutting GH4169 during spray cooling was established, and the tools with designed micro-textures were used in it. The influence of the different micro-texture morphologies on the tool wear was analyzed. Secondly, the designed micro-textured tools with five different morphologies were produced using a femtosecond laser. Cutting experiments were conducted using the micro-textured tools during spray cooling. The wear area of the rake face was measured based on the infinitesimal method, and the optimal morphology with the best anti-wear ability was obtained. This study provides technical support for the design and development of micro-textured tools with an improved cutting performance, and contribute to the promotion and application of micro-textured tools.

Experimental Investigation of the Derivative Cutting When Machining AISI 1045 with Micro-Textured Cutting Tools

In the context of satisfying sustainability requirements nowadays, dry machining is one of the ideal strategies to eliminate the environmental and human health burdens of machining processes. In addition, micro-textured cutting tools are used to improve the performance of dry machining processes. Micro-textures reduce the chip-tool contact length and thus reduce friction and heat, which results in fewer cutting forces and temperature. However, the action of micro-cutting of the bottom side of the chip, which is known as derivative cutting, cuts down the gains of using textured tools, where derivative cutting leads to higher cutting forces, heat, and tool wear. This study aimed to investigate the effects of significant texture design parameters (i.e., micro-groove width) when cutting AISI 1045 steel using different machining parameters (i.e., 75 m/min and 150 m/min of cutting velocity, 0.05 and 0.10 mm/rev of feed). Three different textured cutting tool designs were prepared using the laser texturing technique and then utilized in machining experiments. In addition, the measured machining outputs were forces, power consumption, flank wear, and surface roughness. There were no marks for the derivative cutting when using the textured cutting tool with the narrowest micro-grooves according to the obtained microscopical images after the machining tests. In addition, the textured cutting tool, which included the narrowest micro-grooves, showed better performance compared to the non-textured cutting tool and the other textured tool designs in terms of cutting and feed forces, power consumption, flank tool wear, and surface roughness at the used cutting conditions. This confirmed that the careful optimal design of the micro-textured tools can reduce or eliminate the severity of the derivative cutting, and thus improve the overall machining performance.

The influence of microtexture tools on the geometric morphology of serrated chips based on stress triaxiality

PurposeThis study aims to investigate the effect of microtextured tools on the geometric morphology of serrated chips, and further improve the cutting performance of polycrystalline cubic boron nitride (PCBN) tool and extend the tool life and the surface quality of the machined surface.Design/methodology/approachA three-dimensional finite element cutting model of hardened steel AISI D2 with microtextured PCBN tools were established using the finite element software Abaqus, and cutting tests were carried out. Furthermore, the stress distribution in the primary deformation zone was investigated based on the triaxiality of stress, and the influence of microtexture on the geometric morphology of serrated chips and crack development was researched.FindingsThe results show that compared with nontexture tools, elliptical pits and wavy grooves microtexture tools have lower serrated degree Gs, higher serrated frequency f per unit length and more miniature serrated step Pc. The serrated phenomenon is intensified because the tensile stress zone of chips generated by nontextured tools is longer than that of elliptic pits and wavy grooves microtexture tools. Simultaneously, the maximum value of triaxiality in the tensile stress zone achieved by nontexture tools is larger than that of the two microtexture tools, and chips obtained by nontextured tools are more susceptible to propagation fractures.Originality/valueThis paper mainly studies the effect of microtexture on chip microgeometry, which is relatively little studied at present. At the same time, this paper has a certain engineering significance for PCBN tool turning hardening steel.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0149/

Uniform-Density Micro-Textured Ball-End Milling Cutter Model Based on Fractal and Uniform Distribution Theory

At present, for micro-textured tools, the determination of the micro-texture placement area depends on the derivation of the cutting geometric model. The micro-texture distribution form applies geometric methods, and the research methods and accuracy are limited. Therefore, in this paper, the ball-end milling cutter is taken as the research object. Based on fractal theory, the morphology of the tool before and after wear is compared to determine the tool–chip contact area. The uniform-density micro-texture distribution model is established using the uniform distribution point theorem, and the synergistic mechanism of the edge and the micro-texture is revealed. The strength of the micro-textured tool with uniform density under the action of the edge is studied by simulation. Finally, the determination of the tool–chip contact area and the establishment of a uniform-density micro-texture model is realized. It is proved that the synergistic effect of the cutting edge and the micro-texture has a positive effect on the milling behavior of the tool. When comparing the non-edge and non-texture tools with the cutting-edge tools, the maximum strain and stress of the cutting-edge micro-textured tools increased by 12% and 30%, and 30% and 20%, respectively, without affecting the normal use of the tool. This research provides a new method for the design of micro-textured tools.

Study on noise behavior of micro-textured composite coated cemented carbide surface grinding titanium alloy based on HHT analysis

In modern industrial production, noise can reflect the cutting state of the workpiece and tool to a certain extent, and the noise collection method cannot interfere with the complex processing environment. To further improve the cutting performance of coated cemented carbide micro-textured tools, this paper builds a friction and wear test platform for micro-textured cemented carbide pins with AlSiTiN-AlCrN coating and titanium alloy discs. Based on the test noise signal, the relationship between friction and wear and the noise of the workpiece was studied by the Hilbert–Huang transform (HHT). Through the change of noise in different periods, the micro-texture and coating life of cemented carbide pin under other processing parameters were analyzed. Based on the influence of the interaction between processing parameters and micro-texture diameter on the test results, the test parameters were optimized. The results show that the change of noise signal during the test presents a “V” curve with the grinding process, which mainly affects the noise through the shift of pin-disc friction form and the anti-wear effect of micro-texture. The interaction mainly affects the test results by affecting the micro-texture diameter, laser energy concentration, and the roughness of the inner wall of the pit. The optimized micro-texture geometry and preparation parameters are as follows: scanning times is 8, micro-texture diameter is 50 μm, scanning speed is 1500 mm/s, micro-texture spacing is 170 μm, and laser power is 40 W. The research content of this paper provides a reference for improving the surface properties of cemented carbide.

Investigations on homothetic and hybrid micro-textured tools during turning Inconel-718

ABSTRACT Amused with the blissful benefits of micro-textures, researchers consider it a promising option for improving cutting tool performance, especially during machining superalloys. Through this study, the machining performance of two homothetic and six hybrid micro-textured tungsten carbide inserts have been comparatively assessed while dry turning Inconel-718. Dimple and channel micro-textures were the two independent homothetic textures. Dimple and channel micro-textures with 0°, 45°, and 90° orientation angles and a combination of triangle, square, and dimples constituted six different hybrid micro-textures. Micro-textures were fabricated on the rake face of inserts using a Ti-sapphire fired, nanosecond pulsed, infrared fiber laser. Dimple and channel micro-textured tools at 90° texture angle on rake face performed exceptionally well. Improvements in average tool life, cutting forces, and surface finish have been reported. Adhesion and attrition were the predominant forms of tool wear. Chip morphology study revealed long helical and continuous but segmented chips.

A novel hybrid micro-texture for improving the wear resistance of PCD tools on cutting SiCp/Al composites

In the cutting process of SiCp/Al composites with PCD tools, severe tool wear often occurs, which affects the processing quality and cost. In this paper, the mechanism and effect of the pit, groove and hybrid micro-texture in reducing tool wear were studied. The friction and wear experiments were carried out and evaluated from the aspects of friction coefficient, wear volume and wear mechanism. The results show that the hybrid micro-texture has the best wear reduction effect. In addition, a variety of micro-textures are fabricated on the flank of PCD tools, and milling experiments are designed. The flank wear, tool life, cutting force and lubrication mechanism under different micro-textures are discussed and analyzed, and the anti-wear effect of the hybrid micro-textured tool in the actual cutting process is verified, which is helpful for the application of novel micro-textured tools in cutting SiCp/Al.

Multi-Objective Optimization Design of Micro-Texture Parameters of Tool for Cutting GH4169 during Spray Cooling

This study explores the performance of micro-textured tools when cutting GH4169 during spray cooling. First, the morphologies of the micro-textures were selected according to the simulation and experiments. Secondly, cutting experiments were carried out during spray cooling. As appropriate for each experiment, regression models of cutting force, cutting temperature, or tool wear area were established, and variance analysis was conducted. The cutting force, cutting temperature, and tool wear area functions were obtained from the respective regression models. Based on these functions, the micro-texture parameters were optimized using the response surface method with the cutting force, cutting temperature, and rake face wear area as the objectives. Finally, a full factor experiment on the micro-texture parameters was designed using Minitab, and cutting experiments were conducted using micro-textured tools with these parameters. Taking a relatively low cutting force, cutting temperature, and tool wear as the objectives, a genetic algorithm multi-objective optimization model for the micro-texture parameters of the tools was established, and the model was solved using the NSGA-II algorithm to obtain a Pareto solution set and micro-texture parameters with a good, comprehensive cutting performance. The micro-texture morphology and parameters obtained in this study can also be used for cutting other high-temperature alloy materials with similar properties to GH4169. This research method can also be used to optimize micro-textured tools for cutting other materials.