Page |i

INDEX

Sr. no. Title Page. No

1 Abstract ii -v

2 Introduction vi-viii

3 Methodology ix-x

4 Performance of cutting tool x-xi

5 Method xi-xvii

6 Result and Discussion xviii-xxvi

7 Conclusion xxvii-xxviii

8 Reference xxix
 P a g e | ii

To Study the Effect of Micro Texture Tool

on Cutting

Abstract:
For Titanium:
This paper describes an experimental study conducted to enhance the
cutting performance of titanium alloy Ti-6Al-4V using micro textured
tools. Titanium alloys are difficult to machine due to chip adhesion,
resulting in poor surface quality and tool wear. The study utilized
cemented carbide tools with line, rhombic, and sinusoidal groove
textures on their rake faces. The effects of cutting depth and speed on
feed force and main cutting force were investigated. The results showed
that textured tools generated lower cutting forces compared to non-
textured tools. Among the textured tools, sinusoidal textured tools
performed the best. The wear of the textured tools was significantly
lower due to the micro texture's ability to store and replenish lubricant,
resulting in a continuous lubrication film. The use of textured tools also
improved surface roughness, reducing it by 35.89% when using
sinusoidal textured tools. These findings are valuable for improving
cutting performance and prolonging tool life when machining titanium
alloys with cemented carbide tools.

For aluminium:
Due to environmental obligations on manufacturing industries, there has
been a continuous effort to develop new methodologies targeting
sustainable manufacturing. One such effort is shifting from flooded
lubrication to minimum quantity lubrication and dry machining. It is
estimated that almost 25 to 60% of energy is wasted in the tool-chip and
tool-workpiece interaction zones. The major loss of energy in the
interaction zones is due to friction. The use of lubricants and/or coolants
could potentially solve this problem, but practically it is difficult for the
fluid to penetrate between the interfaces during machining.
To address this problem, micro-texturing of the tool surface has been
proposed. This solution can be beneficial in two ways; firstly, the texture
 P a g e | iii

acts as a reservoir of lubricants in the interaction zone and secondly, it

reduces the actual contact area. Thus, tribological properties are
modified by surface texturing and are utilised to improve the
performance of the cutting tool by reducing the energy losses due to
friction. In this work, surfaces very near to the cutting edge in the rake
face of the tool are textured using micro-EDM and a laser
micromachining. Experimentally it has been demonstrated that textures
can be used to improve the cutting performance of the tool in certain
conditions. There are many investigations of employing texture tools for
the cutting of steels and titanium alloys indicating the beneficial effects of
the texture tools. There are few investigations on the cutting of
aluminium, although the cutting of aluminium occurs extensively. Due to
their differences in material properties, unfortunately, the same
conclusion of beneficial outcomes of using a texture tool for cutting of
steel and titanium may not be translated directly to aluminium without
further investigations. As such, this investigation focuses on the use of
texture tool for cutting of aluminium.
The rake face textures are found to induce significant improvement in
the cutting performances in terms of cutting force decrement and chip
morphology. However, such effects are not observed in flank face
textures for the tested conditions. The texture effect is further
investigated in this thesis under three sections: experimental study,
simulation, and acoustic emission.
In the experimental study, the influence of geometric texture parameters,
such as texture shape and size, depth, pitch, and distance of the
features from the cutting edge, was studied using statistical analysis.
The Taguchi methodology of L9 Orthogonal Array was used for the
experimental study of four texture parameters at three levels. ANOVA
was then used to establish the percentage contributions of significant
texture parameters to cutting forces. Furthermore, the Taguchi
methodology was used to study the effect of the same texture
parameters on other responses, including shear angle, contact area and
percentage concentration of workpiece material on the cutting surface.
The effect on all the responses was finally compared for the given
texture parameters.
To understand the effect of micro-texture and its effective utilisation,
finite element-based simulation using arbitrary ductile fracture for chip
separation was conducted. Abaqus/Explicit software with the Lagrangian
 P a g e | iv

formulation was used for the simulation as it is capable of coupling

material damage and its fracture energy. Simulation results showed a
reduction in cutting forces and similar chip formation characteristics as in
the experimental study. It is attributed that the reduction in cutting forces
and chip curling effect in the rake textured tools are due to the presence
of textures on the rake face, which cause smaller chip tool contact
length, reduced friction coefficient and local lubrication effect.
The acoustic emission study focusses more on the cutting phenomena
involved in the metal cutting process. Cutting involves three phenomena,
namely rubbing, ploughing, and cutting. Generally, rubbing and
ploughing are undesirable effects that cause friction and heat, and thus
wastage of energy supplied. The introduction of texture on the cutting
tool surface can modify or reduce the amount of these undesirable
phenomena. To identify these phenomena which are occurring in the
cutting process, Acoustic Emission (AE) signals were used. The signals
are extracted from the cutting process for non-textured tools, and the
frequencies associated with each phenomenon are determined. The
difference in the contribution of each phenomenon to the textured tool is
then calculated. Such difference gives a measure of the influence of the
texture on the cutting mechanisms, and this can be used to produce
more effective textured tools. In summary, the micro-texture effect on the
cutting tool was demonstrated experimentally, and the contribution of
texture geometry parameters and their distribution was estimated
statistically. Furthermore, the FEM simulation study facilitates the
understanding of the change in cutting mechanisms with the introduction
of texture, which is difficult to observe experimentally. In addition, the
utilisation of AE signals in estimating the change in cutting phenomena
due to texturing of the cutting tool was proposed and evaluated. Finally,
this study gives an overall in-depth analysis of the texture effect in
improving the performance of cutting tools on aluminium.
Aluminium alloy materials are very difficult to break in the processing
process; chip accumulation leads to poor processing stability. In this
paper, a coated composite micro–textured tool is presented. The
influence of coated composite micro–textured tool on chip shape and
cutting force under the same cutting parameters is studied. Firstly, the
combination of cutting force and cutting temperature is optimized based
on cutting test. Secondly, combined with the finite element simulation
technology, three kinds of composite micro–texture tools are tested to
determine the same cutting parameters, tools, and workpiece materials,
 Page |v

and optimize the composite micro–texture combination from the angle of

chip shape, cutting temperature and cutting force. Finally, on the basis of
optimizing the microstructure combination, the optimization of the cutting
performance of aluminium alloy by coating material is studied. It was
found that the chip was more easily broken in the composite
microstructure when two tools were used. The cutting force decreased
by 25% and the cutting temperature decreased by 9.09% compared with
the non–micro–texture tools. The cutting temperature and cutting force
decreased by 3% and 4.99% compared with those of uncoated
composite microstructure.

Keywords:
Textured tool, titanium alloy, cutting performance, cutting force, cutting
fluid, composite micro–texture, chip, coating, cutting temperature.
 P a g e | vi

Introduction

Machining plays a significant role in the manufacturing sector. Most of the

manufactured parts are machined before completion. In machining, the cutting
tool forcefully removes material from the workpiece, and thus the process is
associated with high-stress contact interactions between the tool and the
workpiece. The interactions are in two regions: firstly, between tool-chip and
secondly, between tool-workpiece. It is these tribological interactions that play
a key role in the machining process in terms of machining efficiency, tool life
and surface quality. Although most of the machining processes, namely
turning, milling, and grinding, are generally termed oblique cutting processes
with intricate three-dimensional cutting action, this thesis focuses instead the
orthogonal cutting process. Figure 1.1 gives a better understanding of oblique
and orthogonal cutting. Orthogonal cutting is considered for representing a
two-dimensional cutting process. From this relatively simple two-dimensional
process, the findings from orthogonal cutting can be extended to complex
three- dimensional oblique cutting processes.

Figure 1.1: (a) Orthogonal cutting and (b) Oblique cutting

Figure 1.2 shows a layer of the workpiece with a thickness to, termed uncut
chip thickness, which is removed from the workpiece by the tool. The tool is
moving orthogonally towards the workpiece at speed ‘Vc’, namely the cutting
speed. The two interfaces on the cutting tool with chip and workpiece are
shown in Figure 1.2. The chip of thickness ‘tc’ slides over the rake face of the
tool, which is inclined at an angle ‘α’ (the rake angle) to the cutting velocity
direction.
 P a g e | vii

The rake angle can be negative or positive depending on the specific operation.
The other face is the flank face that is in contact with the newly formed surface
of the workpiece and is usually inclined at an angle (the clearance angle) to
facilitate the formation of a smooth surface.
 P a g e | viii

Improving the machining process is certainly needed for many reasons, as even
a small improvement can have an enormous impact at high production
volume. These reasons include demand for more precise parts, the trend
towards miniaturisation and the need for environmentfriendly manufacturing
process, as current machining process involves lubricants and cutting fluids
that are not environmentally friendly. The performance of the machining
process is associated with various aspects and is gauged based on many
factors. Byrne et al. [3] in Figure 1.3 illustrate the interrelation of machining
performance with tool life, accuracy, surface roughness, cutting force required
and chip breakability.

Figure 1.3: Machining Performance

 P a g e | ix

Methodology and work scope

Micro-textures are created on cutting tool surfaces near the cutting edge
either using EDM or laser micromachining. High speed steel and tungsten
carbide tools have been textured. Texturing is done on rake, flank or both rake
and flank faces of the tool. Dimples and stripes are the two types of textures
investigated in this study. The textured tools are used to cut the workpiece
orthogonally. Both strip cutting and tube cutting were conducted. An
experimental investigation of the texture effect is done in terms of cutting
forces, friction coefficient, shear angle, contact area and adhesivity of
workpiece material on the tool surface. A detailed study of the geometric and
distribution parameters of dimple textured tool is made with the help of the
Taguchi methodology of experimental studies. A tribological study is made to
study the improvement of friction conditions due to the texture in the contact
zone at actual cutting conditions. A FEM (Finite Element Modelling) simulation
model was developed to analyse the texture effect and study the change in
chip formation due to texture introduction. The simulation model is validated
for the observable phenomena, and the validated model has been used to
explain and predict the trends of texture effect in terms of forces,
temperatures, stresses, and strains distribution. A new method for
investigating the texture effect using acoustic emissions was proposed.
 Page |x

Performance of cutting tools

During the metal cutting process, any action that facilitates easy removal of
material in the form of chips will improve the performance of the tool. The
performance of the tool is usually assessed in terms of tool life, the amount of
energy consumed to remove a specific amount of material and the finish
quality of the newly formed surface. These factors are interdependent and are
related to physical factors, such as friction and contact area. A very high
friction occurs as the chip flows over the surface of the tool. The force exerted
due to the relative motion during cutting causes an increase in contact area
between the tool and the chip surface. Relative motion between the chip and
 P a g e | xi

tool surfaces produces frictional heating, resulting in high temperature at their

interface. Sliding speed, high temperature and high pressure in the interface
will produce more wear in the tool. Many methods were tested to reduce
friction and wear in contacting surfaces, which include improvements in tool
geometry, materials, tool coatings cutting parameters, cutting fluids or
lubricants, surface finishing and surface texture enhancement, see Figure 2.1

Figure 2.1: Factors influencing the tool performance.

Surface texture utilisation seems to be attractive because it can make the

manufacturing process more sustainable by reducing or eliminating the need
for lubrication or cutting fluids. There is a possibility of even replacing the need
for coating when textures are developed on the surface to have a friction
coefficient less than the coated surface; such examples can be found in
relation to biomimicking [27]. Micro-textures are utilised for improving the
performance of the cutting tool with the expectation that the micro-textures
will contribute to the followings:
• Reduce friction and improve the tribological conditions in the contact zone.
• Enhance lubrication conditions by acting as local reservoirs.
• Reduce the actual contact area.

Methods used to generate micro/nano textures.

Micro/nano features or textures can be generated on the surface of the tool
by many methods. A suitable method for texture generation must be
determined based on the material, feature size, machine availability,
processing time, cost, accuracy, and repeatability. Table 2.1 lists the possible
methods that are demonstrated to produce micro-features for different
 P a g e | xii

applications, which can be utilised for producing micro-texture in a cutting tool

surface. The methods presented in the table are based on the generation
principle by which the textures are produced, such as removal, addition,
etching, ablation, or deformation. Some of the references cited in the table
demonstrate the texture generation on cutting tools. Though many methods
are available for micro-texturing, each has its advantages and disadvantages.
Important requirement to produce a micro-texture tool is repeatability and
controllability. Considering the minimum feature size, laser and focussed ion
beam machining would be rather appropriate. However, the processing time
and need of vacuum chamber for ion beam machining means that laser
machining will be a better choice for micro/nanoscale textures. As texturing
HSS and WC tools are the key candidates for cutting, both of which are
conductive, EDM appears to be a good candidate in terms of micro size,
repeatability, and controllability. EDM is limited to microfeatures, whereas
picosecond and femtosecond lasers could produce micro as well as nanoscale
features. Out of all these methods for producing micro features, picosecond,
and femtosecond lasers and EDM seem to be promising methods and were
selected to generate micro-textures.
 P a g e | xiii

1) For Titanium
In recent years, titanium alloy has been widely used in aeronautics and
astronautics, and medical, chemical, automotive, and other fields because of
its excellent comprehensive properties. However, titanium alloy is one of the
difficult-to-cut materials due to its high hardness, high strength, low elastic
 P a g e | xiv

modulus, and high chemical activity at high temperature. During the cutting
process, there are a series of problems such as high cutting heat and sharp
friction between the chip and the tool, causing high temperature and pressure
in the cutting zone. As a result, the chip easily adheres to the tool surface,
causing tool wear and reducing tool life.
Lots of research has been carried out to improve tool life and cutting
performance. It was found that tools covered with a durable ceramic coating
can reduce tool wear and improve tool cutting performance.

Materials and Method

Chemical composition of Ti-6Al-4V

Preparation of sample
A titanium alloy bar (Ti-6Al-4V) with a size of Φ100 mm × 150 mm was adopted
as the workpiece in the experiment. Cemented carbide has been widely used
as tool material because of its excellent cutting performance, and a YG8 tool is
adopted in this study. Its physical characteristics are shown in following table.
The geometric parameters of the tool are shown in following table.
 P a g e | xv

To prepare the cemented carbide YG8 tool for surface texture

machining, a pretreatment was performed to minimize surface
roughness. Initially, the tool underwent rough grinding to shape it,
followed by semi-fine grinding and fine grinding using metallographic
sandpapers to achieve a surface roughness Ra of less than 0.1 μm.
Subsequently, the YG8 tool was subjected to a 10-minute ultrasonic
cleaning process and then dried in a self-controlled infrared oven.
Interpublic Group of Companies laser processing technology
(YLPN-1-100-200-R, IPG, New York, NY, USA) was used to machine
the micro textures on the rake face of the YG8 tool. Processing
parameters were determined based on preliminary trials, which are
shown in Table 3. Three types of groove textures (line groove, sinusoidal
groove, and rhombic groove) with the width of 159.599 μm and the depth
of 14.59 μm were fabricated. The surface micrographs of the four tools
used in this study are shown in figure below.
 P a g e | xvi

Figure: Surface micrographs of the four types of tools. (a) Non-textured

tool; (b) Line textured tool; (c) Sinusoidal textured tool; (d) Rhombic
textured tool.
 P a g e | xvii

Equipment and Methods:

The cutting experiments were carried out using a CA6140 lathe. The
main movement was achieved by rotating the titanium alloy bar with the
main shaft, while the feed movement involved both vertical and
horizontal tool motions. The cutting forces were measured using a YDC-
Ⅲ 89A three-direction piezoelectric turning dynamometer. The
experiments followed a single-factor method, and the cutting parameters
are detailed in Table 4. For the experiments, a diluted ZJ-846
concentrated cutting fluid with a ratio of 1:20 was utilized. To ensure
repeatability, each experiment was conducted at least three times.
 P a g e | xviii

Result and Discussion:

• Effect of Cutting Parameters on Cutting Forces: The
main cutting force and feed force were analyzed for four different
tool types across various cutting speeds. As depicted in the figure,
both the main cutting force and feed force exhibited an upward
trend as the cutting speed increased, regardless of the tool type.
This observation can be attributed to the reduction in built-up edge
formation on the rake face as the cutting speed rose.
Consequently, the cutting deformation of the titanium alloy
intensified, leading to an escalation in cutting force. Hence, an
increase in cutting speed corresponded to an increase in cutting
force.

Figure: Main cutting force and feed force of tools at different cutting
speeds (a = 0.3 mm). (a) Main cutting force; (b) Feed force.
Out of the four tools, the sinusoidal textured tool demonstrates the
lowest cutting force. This can be attributed to the orientation of the
sinusoidal micro texture, which is nearly perpendicular to the chip
flow direction. This orientation has two beneficial effects. Firstly, it
reduces the contact area between the chip and the rake face.
Secondly, it facilitates chip breaking, leading to improved chip
control. As a result, the sinusoidal textured tool proves to be more
suitable for cutting titanium alloy due to its ability to generate lower
cutting forces.

• Effect of Tool Type on Chip Morphology: The presence of micro

textures on the tool surface induces a chip breaking effect, which
effectively controls the shape of the chips produced during the
cutting process. This chip control mechanism ensures that the
 P a g e | xix

chips do not wind around the tool, allowing for smooth and
uninterrupted cutting operations. The experimental findings hold
great significance in understanding and remanaging chip control
during cutting. By gaining insights into the impact of micro textures
on chip formation, shape, and size, it becomes possible to enhance
cutting performance by achieving effective chip breakage.

• Effect of Tool Type on the Wear Morphology of the Rake Face:

The utilization of a textured tool has several advantageous effects,
including reducing the tool-chip contact length, cutting process
temperature, work hardening of titanium alloy, and adhesion of
titanium alloy. Consequently, the wear on the tool's rake face is
reduced when micro textured tools are employed. This study holds
significant importance in mitigating the occurrence of sticking
during the cutting of titanium alloys, enhancing tool lifespan, and
minimizing tool wear.

• Effect of Tool Type on the Machined Surface Roughness:

Figure below illustrates the surface roughness Ra of Ti-6Al-4V.
When comparing non-textured tools, line textured tools, sinusoidal
textured tools, and rhombic textured tools, the surface roughness
Ra values obtained are 2.959 μm, 2.246 μm, 1.897 μm, and 2.634
μm, respectively. The surface roughness Ra of the surfaces
machined by the three types of textured tools is lower than that of
the non-textured tool. Specifically, the surface roughness Ra is
reduced by 24.10%, 35.89%, and 10.98% when using line,
sinusoidal, and rhombic textured tools, respectively. Among the
three textured tools, the sinusoidal textured tool produces the best
surface quality for machining Ti-6Al-4V. Therefore, the sinusoidal
textured tool is considered the most suitable option for machining
Ti-6Al-4V.
 P a g e | xx

Figure: Machined surface roughness of titanium alloy

For Aluminium
With the advent of modern manufacturing, processing technology is
advancing towards higher levels of precision and speed. This
necessitates elevated standards for the machining quality and
production efficiency of parts. Aluminium alloy materials are extensively
utilized in various industries such as automotive, shipping, and
aerospace, owing to their exceptional mechanical and thermal
properties. However, due to their low melting point, these materials
undergo plastic deformation when subjected to high temperatures and
pressures during the cutting process. Consequently, the chips generated
during processing tend to overflow and soften, posing a challenge as
they readily adhere to the tool surface. This accumulation significantly
impacts the tool's lifespan, leading to a decline in processing quality.
Consequently, numerous scholars worldwide are focusing on optimizing
tool performance by refining both the tool structure and surface coating.
In recent years, advancements in bionics and tribology have
revealed the exceptional wear resistance and abrasion resistance of
surfaces with microstructures. During the cutting process, the tool's front
surface comes into direct contact with the workpiece material, resulting
in substantial friction and consequent tool wear. Consequently, the
integration of micro-textures on the tool blade has garnered considerable
 P a g e | xxi

attention from scholars. Su et al. conducted a study on the machining

performance of a microgroove tool when cutting titanium alloy. They
observed a significant increase in the friction coefficient between the tool
and chip under dry turning conditions. Rathod et al. investigated the dry
cutting of AL6063 using tools with microstructures and discovered that
these microstructure tools outperformed their non-microstructure
counterparts, resulting in a 30% decrease in cutting force for square
microstructure tools.
 P a g e | xxii

Cutting test
Test materials and Equipment
During the test, the CBN tool was employed, which is a novel artificial
material widely utilized in the cutting industry due to its high hardness
and excellent impact resistance. The performance parameters of the tool
material are presented in Table 1. The workpiece material chosen for the
experiment was AL7075 aluminium alloy, with a diameter of 50 mm and
a length of 250 mm. The performance parameters of the workpiece
material can be found in Table 2. To collect cutting force data, a
CA6140A lathe and a Kistler 2825A-02 high sensitivity piezoelectric
three-way dynamometer was utilized. Additionally, thermal imagers were
employed to measure the cutting temperature generated during the
cutting process. The testing equipment is illustrated in Figure.
7075 aluminium alloy's composition roughly includes 5.6–6.1% zinc,
2.1–2.5% magnesium, 1.2–1.6% copper, and less than a half percent
of silicon, iron, manganese, titanium, chromium, and other metals.
 P a g e | xxiii

The choice of cutting

parameters significantly impacts the generation of cutting heat and the
stability of the cutting process during machining [23]. To ensure both the
appropriate machining parameter range for the CBN tool and the
maintenance of machining accuracy, a cutting test scheme is devised as
outlined in Table 3. Dry cutting is employed for the test.

Figure 2 illustrates the results of the cutting force test. It can be

observed that as the cutting speed decreases, the cutting force gradually
diminishes. The cutting parameters Vc = 125 m/min, f = 0.2 mm/r, and
ap = 0.3 mm yield the minimum cutting force. This reduction in cutting
force can be attributed to the decrease in cutting volume, resulting in a
decrease in the size and shape of the cutting layer. Therefore, the
 P a g e | xxiv

deformation of the workpiece diminishes, leading to a decrease in

cutting force.

Figure 3 displays the entangled chips around the aluminium alloy rod.
Notably, the chips do not spill or stack near the main edge of the cutter.
This extended contact between the chip and the tool exacerbates the
likelihood of chip adhesion, which can adversely affect the cutting
process.

The data collected using a thermal imager are presented in Figure 4,

while the results of the cutting temperature test are shown in Figure 5.
The graphs indicate that the cutting temperature decreases with the
decrease in cutting volume. This decline in temperature is attributed to
the reduced cutting deformation, friction, and contact area, which
enhance the heat dissipation conditions and promote effective cooling of
the tool.
P a g e | xxv
P a g e | xxvi
 P a g e | xxvii

Conclusion
Titanium alloys:-
Under the lubrication condition of cutting fluid, the experiments of cutting
titanium alloy with different cutting speeds and depths were carried out
using YG8 tools with line, rhombic, and sinusoidal groove textures on
the rake face. The main conclusions were as follows:
• Under the same lubrication condition, three types of texture on the
tool rake face were all effective in reducing cutting force and tool
wear. Among the three types of textured tools, the sinusoidal
textured tool caused the best cutting performance, followed by the
line textured tool and rhombic textured tools.
• The decrease of main cutting force can reach up to 30.97% by
using textured tools. The morphology of chips produced by
textured tools is better than that produced by non-textured tools.
The existence of the textures on the tool surface is beneficial for
chip breaking.
• On the rake face of the non-textured tool appears violent adhesive
wear, while adhesive wear of the textured tool is weaker. The
sinusoidal textured tool shows the best anti-adhesion effect among
the four kinds of tools.
• The roughness of the machined surface produced by textured
tools is significantly lower than that of the non-textured tool.
Titanium alloy machined by the sinusoidal textured tool has the
lowest surface roughness, which reduced by 35.8% compared with
that of the non-texture tool.

For aluminium alloys:-

In this paper, the optimal cutting dosage combination is selected by
cutting test, taking cutting force and cutting temperature as the yardstick.
The cutting performance of the composite micro–texture tool is
simulated by means of finite element simulation software combined with
the above optimal cutting quantity. By comparing the cutting
performance of the different optimal composite micro–texture e tool, the
cutting performance of different composite micro–texture tools is
optimized, and coating cutting test is carried out on the preferred
composite micro–texture tool. The results were as follows:
 P a g e | xxviii

• Cutting tools with interlaced pit-convex micro–texture promote

wafer curl and fracture. When the chip flows through the blade, the
fracture overflows and the chip accumulation improve markedly.
• Changes in the distribution of dented tissue in the front of the tool
will cause changes in cutting force and cutting temperature. pit-
convex micro–texture combined with staggered micro–texture has
good cutting performance in reducing cutting force and
temperature.
• Due to the high hardness and chemical stability of the coating
material, it acts as a protective barrier in the event of sharp tool
collisions and further optimizes the cutting performance of the tool.
• The combination of combined micro–texture and surface coating
has solved the processing problem of aluminium alloy material
chip winding with large fluctuations and provided a theoretical
basis for aluminium alloy cutting.
 P a g e | xxix

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