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Experimental Investigation of Concave and Convex Micro-Textures for Improving Anti-Adhesion Property of Cutting Tool in Dry Finish Cutting

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Abstract

Tool-chip adhesion impacts on cutting performance significantly, especially in finish cutting process. To promote cutting tools’ anti-adhesion property, the concave micro-grooves texture (MGT) and convex volcano-like texture (VLT) were fabricated separately on lathe tools’ rake faces by laser surface texturing (LST). Various orientations of MGT and different area densities (9% and 48%) and regions (partial and full) of VLT were considered in textured patterns designing. The following orthogonal cutting experiments, machining of aluminum alloy 5038, analyzed tools’ performances including cutting force, cutting stability, chip shape, rake face adhesion and abrasion. It indicated that under dry finish cutting conditions, MGT contributed to cutting stability and low cutting forces, meanwhile friction and normal force reduced by around 15% and 10%, respectively with a weak correlation to the grooves’ orientation. High density VLT tools, on the other hand, presented an obvious anti-adhesion property. A 5 μm reduction of crater wear’s depth can be observed on textured rake faces after long length cutting and textured rake faces presented half size of BUE regions comparing to the flat tool, however, once the texture morphologies were filled or worn, the anti-adhesion effect could be invalid. The bearing ratio curve was employed to analysis tool-chip contact and durability of textured surfaces contributing to a better understanding of anti-adhesion and enhanced durability of the textured tools.

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Abbreviations

F n :

Normal force

F f :

Friction force

µ :

Friction coefficient at the rake face

X rms :

Root mean square of cutting force

S :

Standard deviation of cutting force

R a :

Average roughness

M r1 :

Peak material component

M r2 :

Valley material component

R k :

Core roughness depth

R pk :

Reduced peak height

R vk :

Reduced valley depth

A 1 :

Material filled peak area

A 2 :

Lubricant filled valley area

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Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Jiangsu University, Zhenjiang, Jiangsu, 212013, China

    Zhengyang Kang, Yonghong Fu, Jinghu Ji, Hao Fu, Shulin Wang & Rui Li

  2. Chengdu Tools Research Institute Co., Ltd., Sichuan, 610500, China

    Yun Chen

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  1. Zhengyang Kang
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Correspondence to Zhengyang Kang.

Additional information

Zhengyang Kang Assistant professor in the School of Mechanical and Power Engineering, Nanjing Tech University, China. His research interest is Surface Texturing and Machining.

Yonghong Fu Full professor in the School of Mechanical Engineering, Jiangsu University, China. His research interest is Laser Micro Machining.

Yun Chen Senior researcher in the Chengdu Tool Research Institute. His research interest is Super-hard Cutting Tools.

Jinghu Ji Associate professor in the School of Mechanical Engineering, Jiangsu University, China. His research interest is Tribological Theory and Testing.

Hao Fu Senior researcher in the Institute of advanced materials, Jiangsu University. His research interest is Material Forming.

Shuling Wang Full professor in the School of Mechanical Engineering, Jiangsu University, China. His research interest is Machining.

Rui Li Senior researcher in the School of Design. His research interest is Human Computer Interaction.

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Kang, Z., Fu, Y., Chen, Y. et al. Experimental Investigation of Concave and Convex Micro-Textures for Improving Anti-Adhesion Property of Cutting Tool in Dry Finish Cutting. Int. J. of Precis. Eng. and Manuf.-Green Tech. 5, 583–591 (2018). https://doi.org/10.1007/s40684-018-0060-3

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  • DOI: https://doi.org/10.1007/s40684-018-0060-3

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