Experimental Investigation of the Derivative Cutting When Machining AISI 1045 with Micro-Textured Cutting Tools

In the context of satisfying sustainability requirements nowadays, dry machining is one of the ideal strategies to eliminate the environmental and human health burdens of machining processes. In addition, micro-textured cutting tools are used to improve the performance of dry machining processes. Micro-textures reduce the chip-tool contact length and thus reduce friction and heat, which results in fewer cutting forces and temperature. However, the action of micro-cutting of the bottom side of the chip, which is known as derivative cutting, cuts down the gains of using textured tools, where derivative cutting leads to higher cutting forces, heat, and tool wear. This study aimed to investigate the effects of significant texture design parameters (i.e., micro-groove width) when cutting AISI 1045 steel using different machining parameters (i.e., 75 m/min and 150 m/min of cutting velocity, 0.05 and 0.10 mm/rev of feed). Three different textured cutting tool designs were prepared using the laser texturing technique and then utilized in machining experiments. In addition, the measured machining outputs were forces, power consumption, flank wear, and surface roughness. There were no marks for the derivative cutting when using the textured cutting tool with the narrowest micro-grooves according to the obtained microscopical images after the machining tests. In addition, the textured cutting tool, which included the narrowest micro-grooves, showed better performance compared to the non-textured cutting tool and the other textured tool designs in terms of cutting and feed forces, power consumption, flank tool wear, and surface roughness at the used cutting conditions. This confirmed that the careful optimal design of the micro-textured tools can reduce or eliminate the severity of the derivative cutting, and thus improve the overall machining performance.