Setting the micro-texture in the cutter–chip contact area of a micro-textured tool rake face can effectively improve the tool’s cutting performance. However, an unreasonable design for the micro-groove morphology and size and the selection of inappropriate cutting parameters will cause a secondary cutting phenomenon during the cutting process. To explore the optimum micro-texture morphology size and cutting parameters, micro-texture self-lubricating ceramic cutting tools with different morphology parameters (micro-texture location distribution: MSTD-1, MSTD-2, MSTD-3; groove spacing: MSTS-1, MSTS-2, MSTS-3; groove width: MSTW-1, MSTW-2, MSTW-3) were formed in situ and by hot pressing sintering, and a dry cutting 40Cr comparison test with a non-textured tool (MST-0) was conducted. The results revealed that the MSTD-2 tool effectively reduced the cutting force, friction factor, and rake face wear and relieved the secondary cutting phenomenon while cutting 40Cr. A theoretical analysis showed that the micro-texture morphology parameters and cutting speed were the main factors affecting the secondary cutting, with a smaller groove width and higher cutting speed associated with a lighter chip impact.
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This work was supported by the Key Research and Development Plan of Shandong Province (2018GGX103006) and the National Science Foundation of China (51675289).
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