The effects of micro-texture shape on serrated chip geometry in the hardened steel AISI D2 cutting process

Abstract Five micro-textures were processed on the rake face of PCBN tools: circular pits, elliptical grooves, transverse grooves, composite grooves, and wavy grooves. The effect of different micro-textures on cutting force, the cutting temperature, the micro-morphology of serrated chips, tool wear and surface roughness were investigated utilizing three-dimensional finite element simulation and cutting tests. The results indicates that micro-textured tools can lower cutting force when compared to non-textured tools, while cutting force varies significantly during the cutting process. Micro-texture can decrease the temperature in the adiabatic shear band, changes the temperature distribution of the rake face, reduce the serrated degree, and increase segmentation frequency. However, it is more prone to cracking. The wear resistance and the surface quality of machined surface of the elliptical grooves and wavy grooves micro-texture are better.