Research on controlling secondary cutting by optimizing the texture-edge distance of micro-textured polycrystalline cubic boron nitride tools

The application of micro-textured cutting tools is often hindered by the occurrence of secondary cutting, which compromises the effectiveness of such tools during machining. To mitigate this phenomenon, this study investigates the influence of texture-edge distance on the secondary cutting behavior of polycrystalline cubic boron nitride tools. Four texture-edge distances (60 µm, 80 µm, 100 µm, and 120 µm) were examined through finite-element method simulations and experimental validation. Key factors such as cutting temperature, stress distribution, cutting forces, surface roughness, and chip morphology were analyzed. The results reveal that tools with excessively small texture-edge distances (e.g. T60) are significantly affected by secondary cutting due to the proximity of the micro-texture to the cutting edge. In contrast, overly large distances (T100, T120) result in diminished texture function, leading to elevated temperatures and stress levels during cutting. The T80 configuration demonstrates an optimal balance, effectively suppressing secondary cutting while enhancing thermal management, thus significantly improving overall cutting performance.