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Effect of micro-textured morphology with different wettabilities on tool cutting performance

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Abstract

Difficult-to-machine materials such as Ni-based superalloy suffer from severe tool wear and poor surface quality; therefore, the cooling mechanism is the key to improving machining performance and reducing the environmental pollution in manufacturing. In the past, plenty of studies verified that the micro-texture on the cutting insert improved the cutting performance under the same cooling condition. The main explanation is that the second generated cracks caused the capillary siphon phenomenon and increased the wettability of the subsurface of the workpiece. In order to investigate the effect of surface wettability differences on the cutting performance of the tool under different micro-textured morphologies, three types of micro-textured CBN tools with pit, linear, and sinusoidal morphologies were fabricated by laser machining technology. Through cutting experiments on Inconel 718 Ni-based superalloy, the cutting force, tool wear, and machined surface roughness of different micro-textured tools were compared and analyzed. The relationship between cutting performance and wettability of different shaped micro-texture was obtained by measuring the contact angle using PT-705B optical angular contact meter. The experimental results show that the presence of surface micro-textures enhances the surface wettability of the tool. It effectively reduces the cutting force and slows down the rake face’s wear and the machined part’s surface roughness. Compared with other morphologies, sinusoidal micro-textured tools show the best cutting performance. Among the four morphologies of micro-textured tools, cutting performance improvement increases with surface wettability. More generally, these primary findings are consistent with research showing that wettability is critical in micro-texture generation for high-performance machining. The conclusion is very much the key component in future attempts to overcome the assumption of the capillary siphon phenomenon on the subsurface of the workpiece.

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Data availability

The datasets generated and/or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This work was supported by the Key Research & Development Projects (Grant Agreement No. 2020ZDZX0025) of Sichuan Province, China and the Key Research & Development Projects (Grant Agreement No. 22DYF3466) of Sichuan Province, China.

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Authors and Affiliations

  1. School of Mechanical Engineering, Sichuan University, No. 24 South Section 1, Yihuan Road, Chengdu, 610065, China

    Zengfeng Duan, Ling Chen & Binbin Li

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  1. Zengfeng Duan
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  2. Ling Chen
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  3. Binbin Li
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Contributions

All authors contributed to the study conception and design. Material preparation, methodology, cutting experiments, writing—original draft, data collection, and analysis were performed by Zengfeng Duan. Validation, investigation, and data curation were performed by Binbin Li. Experimental method guidance and writing — review and editing were performed by Ling Chen. All authors read and approved the final manuscript.

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Correspondence to Ling Chen.

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Duan, Z., Chen, L. & Li, B. Effect of micro-textured morphology with different wettabilities on tool cutting performance. Int J Adv Manuf Technol 123, 1745–1754 (2022). https://doi.org/10.1007/s00170-022-10284-2

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  • DOI: https://doi.org/10.1007/s00170-022-10284-2

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