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    Mechanisms and predictive force models for machining with rake face textured cutting tools under orthogonal cutting conditions

    Year: 2021

    Journal: Int. J. Mech. Sci., Volume 195, APR 1

    Authors: Chen, Yuhan; Wang, Jun; An, Qinglong

    Organizations: China Scholarship Council

    Keywords: Surface texturing; Machining performance; Cutting tools; Surface wettability; Mechanics of cutting; Cutting force models

    The cutting performance and mechanisms of rake face textured carbide cutting tools in orthogonal machining of a carbon steel are investigated. Micro-grooves at 15.5 mu m top width and different depth-to-width ratios are fabricated on the tool rake face using a femtosecond laser. It is found that the textures can significantly enhance the surface wettability of the cuffing tools to an emulsified cuffing fluid, and a fast liquid infiltration along the micro-grooves takes place. The machining tests show that cutting tools with the rake face grooves can reduce the thrust force by up to 14.68% in comparison with the untextured cutting tools, as a result of the decreased frictional force between the tool and chip. It is shown that the reduced tool-chip actual contact area due to the rake face textures and reduced tool-chip contact length due to the thinning of chip are the main reasons for this frictional force reduction. It is further found that the ploughing action between the groove edges and chip material tends to increase the frictional force while the chip material deposition to the textural structures reduces the functionality of the textures. Plausible trends of the reduction of the cutting forces with respect to the textural parameters are discussed, from which grooves in parallel to the cutting edge at 0.6 depth-to-width ratio and about 90 mu m spacing are found to perform the best. A cutting force model for orthogonal machining using rake face textured cutting tools are then developed using the classical thin shear zone theory and the unified mechanics of cutting approach. The model is finally verified experimentally which shows that the model predictions agree well with the corresponding experimental data for cutting with and without a cutting fluid.
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