Sustainable machining using micro-textured cutting tools

Abstract

One of the effective strategies to improve the dry machining processes is the implementation of micro-textured cutting tools. Micro-textures decrease the chip-tool contact length and thus reduce friction and heat which lead to better surface quality and longer tool life. However, micro-cutting of the bottom side of the chip, known as derivative cutting, is an issue when using textured tools. Derivative cutting increases the cutting forces, heat, and ultimately tool wear. This work investigates the effect of micro-texture design parameters on the occurrence of derivative cutting and offers design recommendations when preparing micro-grooves to eliminate/reduce the severity of this phenomenon. Besides, this study investigates the effect of micro-grooves design parameters and cutting velocity on power consumption, flank tool wear, and surface roughness when machining AISI 1045. Moreover, in this study, an Oxely-based analytical model is developed to optimize the micro-textured cutting tool design(s) in a way eliminating the occurrence of derivative cutting. The model accommodates any workpiece material, tool geometry, and machining parameters. The model was validated by orthogonal cutting of AISI 1045 steel tubes. Besides, in this study, a new holistic performance analysis approach was developed and utilized to evaluate the performance of machining using textured and non-textured cutting tools considering the life cycle assessment impacts, the existing sustainable machining elements, and the product quality aspects. The current study offers approaches and design recommendations to achieve a sustainable machining environment with considering the quality of the machined product.