The Optimal Design Of Micro-Textured Turning Tools And Study On Their Cutting Performance

Dry cutting technology conforms to the concept of green manufacturing and the trend of sustainable development of modern manufacturing industry.Without cutting fluid,dry cutting technology puts forward higher requirements for cutting tools.In recent years,introducing micro-textured structures onto the surface of cutting tools is a common and effective method to improve cutting performance of the tools.In this paper,the finite element method(FEM)was used to analyze the influence of the micro texture on the surface stress distribution and cutting performance of the tool.In addition,the micro texture parameters of the tool were optimized,and the excellent cutting performance of the micro-textured cutter was verified through turning experiments.The main research contents are as follows:(1)The micro textures with four different shapes were designed and the tool models were established.The Von Mises stress distribution was obtained after the loading of cutting force by using ANSYS.The best texture shape MT-1(which was a striped texture that parallel to the main cutting edge)was selected out by comparing the stress value and the stress distribution on the rake face of the cutting tool.Based on this shape,the size of the texture was optimized gradually by changing the distance between the edges of the texture,the distance of the texture center,the width of texture,the depth of texture and the shape of the texture cross section.Finally,the structure of the optimized micro-textured tool was obtained after improving the stress distribution on the rake face of the tool: the texture shape is MT-1,the edge distance L=100 ?m,the center distance of the micro texture A=100 ?m,the micro texture width B=50 ?m,the micro texture depth d=25 ?m,and the micro texture cross section shape is V-shaped.(2)Based on previous optimization results,orthogonal experiments with three factors and three levels were carried out to find out the influence law of the texture width,texture depth and edge distance on the cutting performance of the cutter.The cutting process of nine kinds of cutting tools with different texture dimensions were simulated by ABAQUS.The influences of the three factors on cutting force and cutting temperature were explored,and the optimized texture size was obtained: texture width B=25 ?m,texture depth d=10 ?m,edge distance L=50 ?m.Based on this size,the texture area ratio(texture width constant)is optimized.It is found that the texture area ratio of 33.3%~50% is an optimization range when the texture width is 25 ?m.Furthermore,a comparative study of the shape of the texture section was carried out.It is found that the V-shaped texture is more advantageous than that of the rectangular section at different area ratios.(3)The optimized micro-textured structure was fabricated on the rake face of the tool by laser processing technology to prepare the micro-textured tool.Contrastive cutting experiments of the microtextured tool and none-textured tool were carried out at different cutting speeds.The results show that the cutting force of micro-textured cutters can reduce the main cutting force,feed force and radial thrust force by 7%~14%,4%~14% and 3%~12% respectively,and the cutting temperature is reduced by 3%~11%.The test results of the cutting force and cutting temperature were checked with the simulation results,which proves that using the finite element simulation technique to optimize the cutting performance of micro-textured tools is feasible.