Assessment of self-lubricating coated cutting tools fabricated by laser additive manufacturing technology for friction-reduction

Dry cutting acting as a green machining technology is a promising manufacturing process in industrial applications; however, severe friction under dry cutting conditions aggravates tool wear and reduces tool life. Self-lubricating cutting tools exhibit excellent benefits in improving cutting properties and that can be used in sustainable machining. The complex process, low efficiency and thin coating thickness limit the production and use of present self-lubricating cutting tools with traditional methods. To enhance the lubricating effect and motivate the development of fabrication methods for self-lubricating cutting tools, Ni-based powders dispersed with MoS2 and Al2O3 particles were preset on the tool substrate; afterward, the self-lubricating coatings were deposited by laser powder-bed fusion additive manufacturing (AM) with a nanosecond fiber laser for cutting application. The self-lubricating coatings were characterized, and the friction and cutting performances of the AM self-lubricating coated tools (SLCs) were evaluated by sliding friction and dry machining tests. The results show that the developed SLC tools reduced the friction coefficient by 8.8–11.7%, cutting forces by 17.6–29.6%, and cutting power by 17.3–22.0% compared to conventional high-speed steel cutting tools (HSS). Built-up edge formation and tool wear were also significantly reduced. The observed mechanisms were attributed to the release of MoS2 particles from the coatings forming a lubricating film at the tool-chip interface, while the Al2O3 particles enhanced surface hardness. The results revealed the practicability of self-lubricating coated cutting tools fabricated by laser-based AM for friction-reduction, and that provide a cleaner process for dry cutting applications.