Cutting Performance Of Surface Textured Ceramic Tools

According to surface textures have an effect of good anti-friction and wear-resistance, surface textured tools are proposed in this paper. The influence of the characteristic of the surface textures (including the width, the spacing, the depth and the morphology of the textures) on the cutting performance was analyzed through finite element method and cutting tests.The orthogonal cutting of45hardened steel was simulated using a two-dimensional finite model through the software ABAQUS. Results show that surface textures with different width, spacing, depth and morphology have different effects on the cutting performance of cutting tools. When the width of surface textures is change, the AW20tool have the lowest cutting force and cutting temperature. But the secondary-cutting phenomenon, which increased the cutting force and the cutting temperature, weakens the positive effect of the textures, is obvious when the widths of the textures greater than or equal to50μm. The smaller the spacing, the more the number of texture during the tool-chip contact region, the smaller the cutting force and cutting temperature of the tools (the AS30tool), but the worse the strength of the tool. With the small texture spacing, more textures were at the tool-chip contact area, then the cutting force and cutting temperature was low, while the small spacing resulted in poor tool strength. Hardly cutting force varies with the texture depth, only cutting temperature has decreased slightly, as the texture depth increase. And same as the texture width, the large depth resulted in poor tool strength. Considering the cutting force, cutting temperature and strength of the tool, when the textures width, spacing, depth are50μm, under the premise of ensuring the tool strength, the cutting tools performance was improved by the maximum degree. Cutting tests on45hardened steel are carried out with surface textured self-lubricating tools. The result show that: the changing trends of cutting force and cutting temperature are consistent with the simulation results. Although microscale textures have good heat dispersion and anti-friction, but they also cause the second-cutting phenomenon, and they are easily blocked. There is a chamfer with little size, it is very difficult to machine microscale textures on the chamfer. So we combine microscale and nanoscale textures, and we prepared micro/nano-textured tool (AT) and nano-textured tool (AN) to compare with micro-textured tool (AW50). According the FEM results, whether with or without molybdenum disulfide, the AT tool have the excellent performance. Using these three surface textured tools with molybdenum disulfide conduct cutting tests. The principal force, feed force and thrust force of micro/nano-textured self-lubricating tool (ATL) reduced about15-20%,20-25%,15-20%, respectively; meanwhile, the friction coefficient and cutting temperature are reduced effectively.The mechanism of the micro/nano-textured self-lubricated tools improves the cutting performance is analyzed:during the cutting process, the solid lubricants filled in the textures are released and smeared on the tool-chip interface and form a lubricating film, which can reduce the frictional shear strength; meanwhile the micro/nano-textures could reduce the tool-chip contact length. As a result, the conditions of friction and wear during the cutting process are improved.