In-situ forming textured cutting tools based on electrohydrodynamic atomization and laser micro-cladding technology

Abstract

The application of mechanization in different environments has put forward strict requirements for mechanical components, which also means higher requirements for cutting tools. It is precisely these requirements that drive the development of cutting tool preparation methods towards novelty and innovation. To effectively enhance the performance of dry cutting tools, laser micro-cladding technology has been innovatively adopted to achieve additive manufacturing of new textured cutting tools. The mechanical properties, tribological properties, and cutting performance of the newly textured tools were evaluated. The results indicate that the EHDA process can achieve uniformity and thickness controllability of the preset powder layer. In friction experiments, the friction coefficient of textured surfaces can be reduced by up to 44.3% compared to polished surfaces. In the cutting experiment, the cutting force of LCT tools has decreased by up to 26.7%, and the cutting temperature has decreased by a maximum of 32.5%. The research mechanism indicates that at lower cutting speeds, WS₂ forms a lubricating film at the tool-chip contact interface, reducing shear strength and achieving a reduction in cutting force and cutting temperature. And the micro-textures are the main way for the LCT tool to reduce cutting force and cutting temperature at higher cutting speeds.