Micro texture tool (MTT) with variable distribution density was proposed, and the novel MTT can adapt to different friction states in the tool chip contact area and maintain good anti-friction and wear resistance. The novel MTTs were composed of two regions with different groove width and distribution density which were prepared on the rake face by femtosecond laser technology. The cutting process were carried out in turning superalloy GH4202. According to the machining characteristics (rake wear, tool wear volume, workpiece material adhesion volume and the chip morphology), the role of variable distribution density in turning were analyzed. The experimental results show that the texture parameters of the texture region near and away from the edge have different effects and mechanisms on the machining characteristics. Compared with non textured tool and uniform textured tool, the proper design of texture parameters of variable distribution density texture can make the MTT have better wear resistance and chip breaking ability when turning superalloy GH4202.
A novel design method of grooved type micro-textured tool(MTT) was presented. The lubrication and cooling state of the contact area between the rake face and the chip were analyzed. Based on the penetration process and heat transfer process of cutting fluid on the rake face, the tool-chip contact area was divided into low temperature zone(LTZ) and high temperature zone(HTZ). The penetration of cutting fluid along the micro-texture(MT) groove and the penetration perpendicular to the groove in the LTZ were modeled. It is found that the size parameters and distribution density of the MT are related to them. The heat transfer process of cutting fluid and tool in HTZ and were modeled and analyzed. The secondary cutting phenomenon in micro-textured HTZ surface was modeled as well. The relationship between secondary cutting and texture size parameters is established, and the criteria for the occurrence of secondary cutting are proposed. Based on the theory above, MTTs with variable distribution density were designed and prepared. The design and theoretical model were verified in turning nickel-based superalloy GH4202.
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