Study On Cutting Performance Of Dual Micro-textured Tools

Surface texture has been gradually applied to the surface of the tool due to its superior friction reduction and lubrication effect.However,the texture is easily subject to adhesive failure owing to the derivative cutting during the process of cutting,which leads to a decrease in the cutting performance of the tool.In order to extend the durability of the texture,reduce the adhesion of the tool surface,and further improve the cutting performance of the textured tool,this article uses laser micro-texturing technology to process four different types of textures on the rake face of the tool: ring texture(RT),parallel groove texture(PT),vertical groove texture(VT)and dimple texture(DT).According to the role played by different textures during the cutting process,the up-down dual textured dimple-parallel grooves(SXDP),dimple-vertical grooves(SXDV)and the left-right dual textured dimple-parallel grooves(ZYDP),dimple-vertical grooves(ZYDV)are processed in the rake face of the tool.The cutting performance of the dual textured tools and the single textured tools are compared,the results shows that the SXDP tool has the best comprehensive cutting performance.The main research contents and conclusions are as follows.(1)Experimental research on laser micro-texturing.By controlling the energy density,laser machining time,and energy accumulation,respectively,the effect of laser output power,scanning speed and scanning times on the texture morphology is obtained.(2)Finite element simulation of tool cutting performance.The cutting performance of single-textured,non-textured and the ZYDP tool are compared through the finite element simulation.The simulation results show that the reasonable texture can improve the stability of the tool processing.Except for the RT tool,other micro-textured tools can reduce the cutting force,the maximum cutting temperature and the wear depth of the rake face.The chip curl produced by the ZYDP tool is the most uniform,while the bottom of the chip processed by the ordinary tools is the smoothest,and its curl radius is larger than that of texture tools.(3)Experimental research on the cutting performance of the single textured tool.With the increase of the cutting speed,the adhesion area of the rake face gradually increases,while the cutting force and the COF between the tool and chips gradually decrease.Except for the RT tool,the main cutting force,friction coefficient between tool-chip and the degree of chip deformation of other textured tools are lower than those of the ordinary tool.Among them,the main cutting force and the COF of the DT tool are reduced by 25-34% and 4.41%-10.81%,respectively.Compared with the ordinary tools,the adhesion area of the rake face of textured tools is reduced by 31.82-38.86%(RT),42.66-49.05%(VT),46.92-52.47%(PT),53.86-59.85%(DT),respectively.The surface roughness of the workpiece processed by the textured tool is reduced by 3.13-4.59%(VT),10.69-46.51%(PT)and 16.51-19.79%(DT)respectively.Among them,the surface finish of the workpiece processed by the DT tool is the best.In terms of flank wear,the flank of ordinary tools has a wear width of about 62?m,while the flank of textured tools has no obvious wear.(4)Experimental research on cutting performance of the dual textured tools.Under the cutting speed of 120m/min,the main cutting force of the dual textured tools ZYDP and ZYDV are reduced by 6.86% and 4.63% respectively compared with the DT tools.The main cutting force of SXDP and SXDV tools is almost the same as that of the dimple textured tool.Except for the ZYDP tool whose adhesion area is reduced by 10.25% compared with dimple textured tool,the adhesion area on the rake surface of other dual textured tools is larger than that of the dimple textured tool under the same conditions.The ZYDP dual textured tool has the smallest chip thickness deformation and the largest shear angle,which is more conducive to cutting,and its workpiece has the best hardening effect.According to the mechanism of different textures and the friction state of the cutting zone,the dimple-groove dual textures are prosessed on the rake face.It shows that developing a reasonable dual texture can fuether reduce the adhesion wear of the rake face and significantly improve the tool cutting performance.