Effect of Micro-Texture on Cutting Performance of PCBN Cutter

Abstract

The research aimed to delve into the intricate relationship between surface microtexture and the cutting performance of a PCBN cutter. In pursuit of this goal, the study implemented three distinct microtextures on the forefront of the turning tool, each of diverse forms. To comprehensively understand the impact, a 3D model was meticulously constructed for simulation purposes. Subsequently, these microtextures were translated into physical form on the tool’s exterior using laser machining, enabling the researchers to conduct real turning experiments. The experimental phase was designed with precision, maintaining consistent environmental conditions across all tests. The primary focus of these experiments was to investigate the forces generated during the turning process. Additionally, the study explored the stress distribution on the tool’s surface and evaluated the texture of the workpiece after machining. The findings revealed valuable insights into the role of microtextures in altering stress dynamics. Specifically, a tool featuring microtexture on its front exhibited a reduction in stress values, strategically shifting the stress focus from the tool’s tip to the microtexture location on the forefront. Moreover, concerning the texture of the workpiece’s surface post-machining, the tool with parallel groove microtexture demonstrated a noteworthy 21% decrease in surface roughness. The study highlighted the pivotal role of surface microtextures in shaping the performance of a lathe tool. These microtextures were identified as agents capable of modifying the immediate friction between the tool and its chip, thereby diminishing surface friction, cutting force, and post-machining surface roughness. The operational stability of lathe machining was also enhanced through these microtextures. Notably, the microtexture characterized by parallel grooves demonstrated a significant improvement in chip-guiding capacity by aligning with the chip flow direction during cutting. The presented research provided a nuanced understanding of how microtextures on a lathe tool’s surface can be strategically employed to optimize cutting performance, offering potential advancements in the field of machining technology.