Study on the mechanism of inhibitory effect of composite micro-textures on derivative cutting

Abstract

It is found after years of research that micro-textured tools have a wide range of application prospects due to their ability to improve the cutting performance effectively. The derivative chips generated during the derivative cutting by micro-textured tools are primarily responsible for the micro-texture failure. In this work, a multi-scale composite micro-texture (MSC-MT) is mathematically modeled for exploring its mechanism of inhibiting derivative cutting. The feasibility of the MSC-MT configuration to inhibit the derivative cutting was verified through the simulation of multi-scale cutting, spanning from micro to macro cutting conditions. The performance of the MSC-MT configured tool was evaluated in comparison to that of the pit-type micro-texture (PT-MT) configured tool by conducting a series of comparative experiments, which included the comparison of life and two-dimensional orthogonal cutting. The formation of derivative chips was also monitored and recorded by high-speed photography. Derivative chips were generated in the PT-MT configuration upon diverting the chips under the action of the chip diversion point, while the back-slope of the MSC-MT configuration allowed the chips to flow directly out of the micro-texture.