Performance of carbide tools with textured rake-face filled with solid lubricants in dry cutting processes

Abstract Surface texturing with different geometrical characteristics was made on the rake face of the WC/Co carbide tools, molybdenum disulfide (MoS 2 ) solid lubricants were filled into the textured rake-face. Dry cutting tests were carried out with these rake-face textured tools and a conventional tool. The effect of the texture shape on the cutting performance of these rake-face textured tools was investigated. Results show that the cutting forces, cutting temperature, and the friction coefficient at the tool-chip interface of the rake-face textured tools were significantly reduced compared with that of the conventional one. The rake-face textured tool with elliptical grooves on its rake face had the most improved cutting performance. Two mechanisms responsible were found, the first one is explained as the formation of a lubricating film with low shear strength at the tool-chip interface, which was released from the texturing and smeared on the rake face, and served as lubricating additive during dry cutting processes; the other one was explained by the reduced contact length at the tool-chip interface of the rake-face textured tools, which contributes to the decrease of the direct contact area between the chip and rake face.

[1]  D. G. Teer,et al.  Performance of MoS2/metal composite coatings used for dry machining and other industrial applications☆ , 2000 .

[2]  Bin-shi Xu,et al.  Solid Lubrication Materials , 2012 .

[3]  D. Jianxin,et al.  Performance of PVD MoS2/Zr-coated carbide in cutting processes , 2008 .

[4]  Noboru Morita,et al.  Development of cutting tools with microscale and nanoscale textures to improve frictional behavior , 2009 .

[5]  Ian M. Hutchings,et al.  Hydrodynamic lubrication of textured steel surfaces under reciprocating sliding conditions , 2007 .

[6]  M. C. Shaw.  Metal Cutting Principles , 1960 .

[7]  M. Olsson,et al.  Abrasive wear of texture-controlled CVD α-Al2O3 coatings , 2007 .

[8]  Song Wenlong,et al.  Design, fabrication and properties of a self-lubricated tool in dry cutting , 2009 .

[9]  T. Aizawa,et al.  Self-lubrication mechanism via the in situ formed lubricious oxide tribofilm , 2005 .

[10]  I. Etsion,et al.  Testing piston rings with partial laser surface texturing for friction reduction , 2006 .

[11]  A. A. Voevodin,et al.  Laser surface texturing for adaptive solid lubrication , 2006 .

[12]  Y. Ochi,et al.  Friction and Wear Test of Titanium Boride Ceramics at Elevated Temperatures , 1993 .

[13]  Jiajun Liu,et al.  The cutting performance and wear mechanism of ceramic cutting tools with MoS2 coating deposited by magnetron sputtering , 1999 .

[14]  C. Ducros,et al.  Effect of DLC surface texturing on friction and wear during lubricated sliding , 2010 .

[15]  Richard T. Haasch,et al.  Surface texturing for adaptive solid lubrication , 2008 .

[16]  L. Geppert,et al.  Performance and limitations of MoS2/Ti composite coated inserts , 2003 .

[17]  A. Liu,et al.  Friction and wear behaviors of the carbide tools embedded with solid lubricants in sliding wear tests and in dry cutting processes , 2011 .

[18]  Ali Erdemir,et al.  Review of engineered tribological interfaces for improved boundary lubrication , 2005 .

[19]  Lev Rapoport,et al.  Surface texturing using pulsed air arc treatment , 2007 .

[20]  Liu Jianhua,et al.  Self-lubrication of sintered ceramic tools with CaF2 additions in dry cutting , 2006 .

[21]  D. Jianxin,et al.  Tribological behaviors of hot-pressed Al2O3/TiC ceramic composites with the additions of CaF2 solid lubricants , 2006 .

[22]  Yoshiteru Yasuda,et al.  Effect of surface texturing on friction reduction between ceramic and steel materials under lubricated sliding contact , 2003 .

[23]  P. Vamsi Krishna,et al.  Performance evaluation of solid lubricants in terms of machining parameters in turning , 2008 .

[24]  Akira Kohyama,et al.  Effect of geometrical parameters in micro-grooved crosshatch pattern under lubricated sliding friction , 2010 .

[25]  T. J. Allen,et al.  Advantages of using self-lubricating, hard, wear-resistant mos2-based coatings , 2001 .

[26]  Toshiyuki Enomoto,et al.  Improving anti-adhesive properties of cutting tool surfaces by nano-/micro-textures , 2010 .

[27]  Deng Jianxin,et al.  Self-lubricating behaviors of Al2O3/TiB2 ceramic tools in dry high-speed machining of hardened steel , 2005 .

[28]  Mohammed Nouari,et al.  Development of electrostatic solid lubrication system for improvement in machining process performance , 2010 .

[29]  S. Lei,et al.  A study of micropool lubricated cutting tool in machining of mild steel , 2009 .