Evaluation of cutting performance of microtextured PCD tools on particle-reinforced titanium matrix composites

Abstract

The preparation of a microtexture morphology on a tool surface can enhance the cutting performance of the tool, and extend tool life, making it an important research direction. In this study, a microtexture morphology was prepared on the surface of a polycrystalline diamond (PCD) tool. The contact angles of different cutting fluids on the microtextured surface were measured to evaluate the influence of the microtexture morphology on the wettability of the tool surface. Additionally, a cutting test of the microtextured PCD tool on particle-reinforced titanium matrix composites (PTMCs) was conducted under minimum quantity lubrication (MQL). Both experimental and simulation analyses indicate that this microtexture morphology has a negligible effect on tool strength. Lubricity tests indicate that the parallel and vertical contact angles of the microtextured tool (TT) are 12 % and 6 % lower than those of the conventional tool (CT), respectively. This suggests that the microtexture enhances the wettability of the PCD tool surface, resulting in improve wear reduction during cutting. Additionally, cutting experiments show that compared with CT tools, TT tools can reduce the cutting force and degree of tool wear and cutting stability, and alter the chip flow direction, thus improving the antisticking effect during machining. To investigate the cutting mechanisms of microtextured tools, the cutting performance of various microtextured tools was compared using the finite element (FE) method. Simulation results show that PCD tools with microtexture morphology can reduce the interaction between the microtextured surface and chip, as evidenced by a reduction in the actual contact area, and that the particles with a textured morphology can act as a support and roll between the chip and tool surface.