Sustainable machining of aluminum MMCs: The role of biomimetic textured cutting tools in cryogenic conditions

Abstract

This study evaluated the feasibility of laser-textured biomimetic designs for cutting tools to investigate the effects of laser-textured tools combined with cryogenic cooling using liquid nitrogen (LN₂) on the tool-chip interface, built-up edge (BUE) formation, and friction during Al-MMC machining. This study involved selecting a biomimetic design, converting it into a textured cutting tool, evaluating the coefficient of friction (CoF) and cutting forces on the textured surface under dry conditions, and using cryogenic LN₂ as a coolant with the textured tool. Femtosecond lasers were used to precisely create biomimetic surfaces near the rake face edge without compromising tool integrity. The pin-on-disc method revealed no significant CoF difference between plain and textured tools or among textured tools within the determinate pin load impact. Dry machining tests showed a higher CoF than the pin-on-disc method owing to strong workpiece material adhesion. Cutting force analysis under dry and textured conditions showed negligible effects on aggregate force components, although textured tools had a higher feed force than untextured ones. Cryogenic cooling with plain tools reduced BUE height, TCC_length, and TCCarea compared to dry conditions. Textured tools in dry conditions increased BUE height and acted as chip breakers, reducing TCC_length and TCCarea compared to dry plain tools. Most textured tools with cryogenic cooling reduced the BUE height, TCC_length, and TCC_area compared to their dry-textured counterparts. The findings suggest that combining biomimetic textured cutting tools with cryogenic machining is a promising approach for sustainable manufacturing of Al-MMC's.