Abstract:
The tool surface texture was a feasible method for modifying cutting friction behavior, and when combined with cutting fluids, it could further enhance lubrication performance and reduce material adhesion. By constructing models of serrated textured tools of three different sizes, the cutting processes of SiC textured tools with Ni and Cu metallic workpieces in vacuum and water environments were simulated. The results showed that during dry cutting, the textured tool caused the normal stress fluctuation to exhibit peak and depression points at the bottom of the texture, whereas friction stress distributions exhibit periodic fluctuations with a period corresponding to the texture width. These fluctuations were significantly greater than those observed with conventional tools and increased with texture width. In a water environment, textured tools effectively fill with liquid, reducing direct contact between the tool and the chip, significantly decreasing stress fluctuations, and showing a significant positive correlation between normal and friction stress fluctuations and metal sticking tool tendencies. With respect to cutting friction, textured tools increase the friction coefficient in dry cutting, whereas in water environments, they extend the HL stage but slightly increased friction during this phase, with both effects intensifying as the texture width increased. This study extended the “stress fluctuation-sticking tool” theory to the field of textured tools, providing a theoretical basis for improving sticking tool phenomena through textured tools.