Numerical Investigation of Microtexture Cutting Tool on Hydrodynamic Lubrication

Abstract

The aim of this technical brief is to provide a numerical approach to investigate the lubricity enhancement effect of microgrooves texture on tools' rake face. The key parameters related to cutting condition and grooves morphology were considered in the analytical model of tool–chip friction pair. The fully textured surfaces with the periodic microgrooves were systematically studied by solving the nondimensional Reynolds equation with the multigrid method. The results indicated that the microgrooves texture generates extra carrying capacity comparing to the flat tool and the optimum grooves direction is vertical to the chip sliding. Higher area density and optimum grooves width can further promote hydrodynamic lubrication. By modifying the tool rake face geometry to restrict the tool–chip slope angle, efficiency of surface texture could be greatly extended. In addition, the film's average pressure was nearly proportional to the chip velocity. Hence, the textured tool is more effective in high-speed cutting.