A novel hybrid micro-texture for improving the wear resistance of PCD tools on cutting SiCp/Al composites

In the cutting process of SiCp/Al composites with PCD tools, severe tool wear often occurs, which affects the processing quality and cost. In this paper, the mechanism and effect of the pit, groove and hybrid micro-texture in reducing tool wear were studied. The friction and wear experiments were carried out and evaluated from the aspects of friction coefficient, wear volume and wear mechanism. The results show that the hybrid micro-texture has the best wear reduction effect. In addition, a variety of micro-textures are fabricated on the flank of PCD tools, and milling experiments are designed. The flank wear, tool life, cutting force and lubrication mechanism under different micro-textures are discussed and analyzed, and the anti-wear effect of the hybrid micro-textured tool in the actual cutting process is verified, which is helpful for the application of novel micro-textured tools in cutting SiCp/Al.