An approach to predict derivative-chip formation in derivative cutting of micro-textured tools

  • Ran Duan
  • Jianxin Deng
  • Dongliang Ge
  • Xing Ai
  • Yayun Liu
  • Rong Meng
  • Jintao Niu
  • Guijie Wang


Derivative cutting of micro-textured tool refers to the additional cutting to the bottom side of the chip with the micro-surface textures on the tool surface. In our previous research, it has been proved that piling up of chip in the microgroove of textures is caused by derivative cutting, resulting in structural function failure of the textured tool face. Hence, derivative-cutting behavior needs to be understood and implemented in models. In this study, an analytical approach for the orthogonal cutting process is developed to determinate derivative-chip formation by predictions of the uncut derivative-chip thickness (UDCT) and minimum uncut derivative-chip thickness (MUDCT) values according to cutting parameters, tool geometry, workpiece material properties, and positional and geometrical parameters of textures. The analytical approach is experimentally validated using a 1045 steel workpiece with the textures of different distances to the main cutting edge on the tool rake face. Subsequently, the responses of the UDCT and MUDCT to cutting speed and texture parameters including its geometry and position are quantified on the basis of the proposed approach. Results show that reasonable enlarging of texture-edge radius and proper increasing of cutting speed both are feasible ways to prevent derivative-cutting from derivative-chip formation.


Derivative cutting Derivative-chip formation Uncut derivative-chip thickness Minimum uncut derivative-chip thickness 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.



This work is supported by the National Natural Science Foundation of China (51675311) and Development Plan of Science and Technology of Shandong Province (2017GGX30115).


  1. 1.
    Xie J, Luo M, He J, Liu X, Tan T (2012) Micro-grinding of micro-groove array on tool rake surface for dry cutting of titanium alloy. Int J Precis Eng Manuf 13:1845–1852CrossRefGoogle Scholar
  2. 2.
    Ma J, Duong H, Lian Y, Lei S (2015) Assessment of microgrooved cutting tool in dry machining of AISI 1045 steel. J Manuf Sci Eng 137:031001CrossRefGoogle Scholar
  3. 3.
    Deng J, Lian Y, Wu Z, Xing Y (2013) Performance of femtosecond laser-textured cutting tools deposited with WS2, solid lubricant coatings. Surf Coat Technol 222:135–143CrossRefGoogle Scholar
  4. 4.
    Ling T, Liu P, Xiong S, Grzina D, Cao J, Wang J, Xia C, Talwar R (2013) Surface texturing of drill bits for adhesion reduction and tool life enhancement. Tribol Lett 52:113–122CrossRefGoogle Scholar
  5. 5.
    Li Y, Deng J, Chai Y, Fan W (2016) Surface textures on cemented carbide cutting tools by micro EDM assisted with high-frequency vibration. Int J Adv Manuf Technol 82:2157–2165CrossRefGoogle Scholar
  6. 6.
    Enomoto T, Sugihara T (2011) Improvement of anti-adhesive properties of cutting tool by nano/micro textures and its mechanism. Procedia Eng 19:100–105CrossRefGoogle Scholar
  7. 7.
    Jahan M, Rahman M, Wong Y (2011) A review on the conventional and micro-electrodischarge machining of tungsten carbide. Int J Mach Tools Manuf 51:837–858CrossRefGoogle Scholar
  8. 8.
    Xie J, Li Y, Yang L (2015) Study on 5-axial milling on microstructured freeform surface using the macro-ball cutter patterned with micro-cutting-edge array. CIRP Ann Manuf Technol 64:101–104CrossRefGoogle Scholar
  9. 9.
    Kumar Pal V, Choudhury SK (2014) Fabrication and analysis of micro-pillars by abrasive water jet machining. Procedia Mater Sci 6:61–71CrossRefGoogle Scholar
  10. 10.
    Chang W, Sun J, Luo X (2011) Investigation of microstructured milling tool for deferring tool wear. Wear 271:2433–2437CrossRefGoogle Scholar
  11. 11.
    Lei S, Devarajan S, Chang Z (2009) A study of micropool lubricated cutting tool in machining of mild steel. J Mater Process Technol 209:1612–1620CrossRefGoogle Scholar
  12. 12.
    Lei S, Devarajan S, Chang Z (2009) A comparative study on the machining performance of textured cutting tools with lubrication. J Mater Process Technol 2:401–413Google Scholar
  13. 13.
    Fatima A, Mativenga P (2015) A comparative study on cutting performance of rake-flank face structured cutting tool in orthogonal cutting of AISI/SAE 4140. Int J Adv Manuf Technol 78:2097–2106CrossRefGoogle Scholar
  14. 14.
    Deng J, Wu Z, Lian Y, Qi T, Cheng J (2012) Performance of carbide tools with textured rake-face filled with solid lubricants in dry cutting processes. Int J Refract Met Hard Mater 30:164–172CrossRefGoogle Scholar
  15. 15.
    Xing Y, Deng J, Wang X, Ehmann K, Cao J (2016) Experimental assessment of laser textured cutting tools in dry cutting of aluminum alloys. J Manuf Sci Eng 138:071006CrossRefGoogle Scholar
  16. 16.
    Sugihara T, Enomoto T (2012) Improving anti-adhesion in aluminum alloy cutting by micro stripe texture. Precis Eng 36:229–237CrossRefGoogle Scholar
  17. 17.
    Obikawa T, Kani B (2012) Micro ball end milling of titanium alloy using a tool with a microstructured rake face. JAMDSM 6:1121–1131CrossRefGoogle Scholar
  18. 18.
    Zhang K, Deng J, Xing Y, Li S, Gao H (2015) Effect of microscale texture on cutting performance of WC/Co-based TiAlN coated tools under different lubrication conditions[J]. Appl Surf Sci 326:107–118CrossRefGoogle Scholar
  19. 19.
    Xie J, Luo M, Wu K, Yang L, Li D (2015) Experimental study on cutting temperature and cutting force in dry turning of titanium alloy using a non-coated micro-grooved tool. Int J Mach Tools Manuf 73:25–36CrossRefGoogle Scholar
  20. 20.
    Xing Y, Deng J, Zhao J, Zhang G, Zhang K (2014) Cutting performance and wear mechanism of nanoscale and microscale textured Al2O3/TiC ceramic tools in dry cutting of hardened steel. Int J Refract Met Hard Mater 43:46–58CrossRefGoogle Scholar
  21. 21.
    Xing Y, Deng J, Li S, Yue H, Meng R, Gao P (2014) Cutting performance and wear characteristics of Al2O3 /TiC ceramic cutting tools with WS2/Zr soft-coatings and nano-textures in dry cutting. Wear 318(1–2):12–26CrossRefGoogle Scholar
  22. 22.
    Enomoto T, Watanabe T, Aoki Y, Ohtake N (2007) Development of a cutting tool with micro structured surface. Nippon Kikai Gakkai Ronbunshu C Hen/Trans Jpn Soc Mech Eng C 73:1560–1565CrossRefGoogle Scholar
  23. 23.
    Enomoto T, Sugihara T (2010) Improving anti-adhesive properties of cutting tool surfaces by nano−/micro-textures. CIRP Ann Manuf Technol 59:597–600CrossRefGoogle Scholar
  24. 24.
    Sugihara T, Enomoto T (2009) Development of a cutting tool with a nano/micro-textured surface-improvement of anti-adhesive effect by considering the texture patterns. Precis Eng 33:425–429CrossRefGoogle Scholar
  25. 25.
    Zhang K, Deng J, Meng R, Gao P, Yue H (2015) Effect of nano-scale textures on cutting performance of WC/Co-based Ti55Al45N coated tools in dry cutting. Int J Refract Met Hard Mater 51:35–49CrossRefGoogle Scholar
  26. 26.
    Zhang K, Deng J, Sun J, Jiang C, Liu Y (2015) Effect of micro/nano-scale textures on anti-adhesive wear properties of WC/Co-based TiAlN coated tools in AISI 316 austenitic stainless steel cutting. Appl Surf Sci 355:602–614CrossRefGoogle Scholar
  27. 27.
    Zhang K, Deng J, Lei S, Yu X (2016) Effect of micro/nano-textures and burnished MoS2, addition on the tribological properties of PVD TiAlN coatings against AISI 316 stainless steel. Surf Coat Technol 291:382–395CrossRefGoogle Scholar
  28. 28.
    Duan R, Deng J, Ai X, Liu Y, Chen H (2017) Experimental assessment of derivative cutting of micro-textured tools in dry cutting of medium carbon steels. Int J Adv Manuf Technol 92:3531–3540Google Scholar
  29. 29.
    Hills D, Nowell D, Sackfield A (1993) Mechanics of elastic contacts. Butterworth Heinemann, LondonMATHGoogle Scholar
  30. 30.
    Zorev N (1958) Results of work in the field of the mechanics of the metal cutting process, Proceedings of the IME Conf Tech Eng Manuf, London, 255Google Scholar
  31. 31.
    Oxley P (1989) The mechanics of machining: an analytical approach to assessing machinability. Ellis Horwood, ChichesterGoogle Scholar
  32. 32.
    Kim C, Bono M, Ni J (2002) Experimental analysis of chip formation in micromilling. Trans NAMRI 129:247–254Google Scholar
  33. 33.
    Chae J, Park S, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46:313–332CrossRefGoogle Scholar
  34. 34.
    Malekian M, Mostofa M, Park S, Jun M (2012) Modeling of minimum uncut chip thickness in micro machining of aluminum. J Mater Process Technol 212:553–559CrossRefGoogle Scholar
  35. 35.
    Son S, Han S, Ahn J (2005) Effects of the friction coefficient on the minimum cutting thickness in micro cutting. Int J Mach Tools Manuf 45:529–535CrossRefGoogle Scholar
  36. 36.
    Yuan Z, Zhou M, Dong S (1996) Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining. J Mater Process Technol 62:327–330CrossRefGoogle Scholar
  37. 37.
    Karpat Y, Özel T (2006) Predictive analytical and thermal modeling of orthogonal cutting process—part I: predictions of tool forces, stresses, and temperature distributions. J Manuf Sci Eng 128:33–36Google Scholar
  38. 38.
    Childs T (1998) Material property needs in modeling metal machining. Mach Sci Technol 2:303–316CrossRefGoogle Scholar
  39. 39.
    Özel T, Altan T (2000) Determination of workpiece flow stress and friction at the chip–tool contact for high-speed cutting. Int J Mach Tools Manuf 40(1):133–152CrossRefGoogle Scholar
  40. 40.
    Johnson G, Cook W (1983) A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. Proceedings of the 7th International Symposium on Ballistics 21: 541–547Google Scholar
  41. 41.
    Jaspers S, Dautzenberg J (2002) Material behaviour in conditions similar to metal cutting: flow stress in the primary shear zone. J Mater Process Technol 122:322–330CrossRefGoogle Scholar
  42. 42.
    Zorev N (1963) Inter-relationship between shear processes occurring along tool face and shear plane in metal cutting. Int Res Prod Eng:42–49Google Scholar
  43. 43.
    Autenrieth H (2010) Numerische Analyse der Mikrozerspanung am Beispiel von normalisiertem C45E [M]. Shaker, AachenGoogle Scholar
  44. 44.
    DeVor R, Kapoor S (2004) On the modeling and analysis of machining performance in micro-endmilling, part I: surface generation. J Manuf Sci Eng 126:685–694CrossRefGoogle Scholar
  45. 45.
    Liu X, DeVor R, Kapoor S (2006) An analytical model for the prediction of minimum chip thickness in micromachining. J Manuf Sci Eng 128:474–481CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  • Ran Duan
    • 1
  • Jianxin Deng
    • 1
  • Dongliang Ge
    • 1
  • Xing Ai
    • 1
  • Yayun Liu
    • 1
  • Rong Meng
    • 1
  • Jintao Niu
    • 1
  • Guijie Wang
    • 1
  1. 1.Department of Mechanical EngineeringShandong UniversityJinanPeople’s Republic of China

Personalised recommendations