Finite element investigation of friction and wear of microgrooved cutting tool in dry machining of AISI 1045 steel

Abstract

This article studies the tribological performance of microgrooved cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using finite element simulation. The purpose is to examine the effects of microgrooves on friction and wear of the textured tools and to compare it with non-textured cutting tools. For the cemented carbide (WC/Co) cutting inserts, microgrooves are designed on the rake face. Specifically, the following groove parameters are examined: groove width, groove depth, and edge distance (the distance from the cutting edge to the first groove). Their effects are assessed in terms of friction coefficient and wear on the rake face. It is found that microgrooved cutting tools can significantly reduce friction and wear in machining, which is attributed mainly to the reduced chip–tool contact length.