Manufacturing technologies
Manufacturing, Metal cutting, In-situ observation

Direct observations of tribological behavior in cutting with
textured cutting tools
Department of Mechanical Engineering, Graduate School of Engineering
Associate Professor Tatsuya Sugihara
https://researchmap.jp/t.sugihara

Abstract
As widely reported in the literature, the micro-texturing technique
has a significant potential to improve the performance of cutting
tools by reducing cutting forces, friction, temperature, and tool
wear, and further, by improving tribological behavior at the toolchip and tool-workpiece interface. However, it is also known thatthe effects of textures on the cutting tool surface strongly dependon the texture geometry and dimensions, and that the applicationof indiscriminate surface textures to cutting tools often results inadverse effects on cutting performance, indicating that an improved understanding of surface phenomena is required to further
develop textured cutting tools. To overcome this situation, thisstudy describes how the textured surface on a cutting tool affects
the deformation fields during the cutting process, including boththe primary and secondary shear zones, by means of direct in-situ
observation using PIV analysis.

Fig. 1 Concept of the textured cutting tool

Manufacturing technologies▍ Background & Results
Surface texturing technology has recently attracted a great
deal of attention as a means of improving tribological behavior at
the tool-chip/workpiece interface in the cutting process (Fig. 1).
However, despite the body of prior work that clearly shows thesignificance of texture designs, there are no specific guidelines fordesigning effective textures for cutting tool surfaces, indicating thatan improved understanding of surface phenomena is required tofurther develop textured cutting tools. This study describes how thetextured surface of a cutting tool influences the deformation fieldsof the workpiece material, including both primary and secondary
shear zones, by means of direct in-situ observation using particle
image velocimetry analysis to understand the behavior in the vicinity of the textured surfaces during the cutting process (Fig. 2). The
experimental results with the textured cutting tool reveal that theeffect of the grooved rake face on the cutting force differs depending on the relative position of the microgroove with respect to theundeformed chip thickness. The friction condition and where thetexture is located determine the performance of the surface texture(Fig. 3).

Fig. 2 In-situ observation of the metal cutting process▍ Significance of the research and Future perspective
In recent years, various challenges, such as dry machining,high-speed machining, and machining of difficult-to-cut materials,
have been emerges in the field of metal cutting. On the other hand,
our study clearly shows that the technology of applying surface
textures to cutting tool surfaces has significant potential to achieve
high-performance machining in various applications in the field ofmanufacturing.

Fig. 3 Material flow in the vicinity of the cutting point

P a t e n t
Sugihara, Tatsuya; Kobayashi, Ryota; Enomoto, Toshiyuki. Direct observations of tribological behavior in cutting with textured cutting tools, International
Journal of Machine Tools and Manufacture, 2021, Vol. 168, 103726, doi: 10.1016/j.ijmachtools.2021.103726
URL http://www-cape.mech.eng.osaka-u.ac.jp/
K e y w o r d metal cutting, in-situ observation, tribology
Tr e a t i s e