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Dry cutting is an effective method to realize the concept of green cutting today. However, in the process of cutting bearing steel, the high temperatures and high pressures produced by the cutting tool and chip under dry friction seriously affect the machining performance of the tool. Therefore, a bionic microstructure tool based on bionics is proposed to improve the cutting performance and reduce friction by changing the size parameters of the microstructure. On the basis of finite element simulation and cutting tests, the cutting force, surface roughness, and chip shape are used to evaluate the cutting performance. It is found that composite bionic micro-textured tools have a significantly reduced cutting force compared with non-micro-textured tools; composite bionic micro-textured tools lead to a reduction in surface roughness of 10–25%; and composite bionic micro-textured tools are more prone to enhancing the curling and breaking of chips. In addition, with the increase in the microstructure area occupancy, the cutting performance of the tool was also significantly improved. Moreover, it was found that the cutting performance of the tool was improved when the area occupancy of the micro-texture on the front face of the tool was increased. [ABSTRACT FROM AUTHOR]

In order to solve the problem of poor stability of hard brittle material in cutting process, a 45° groove micro-textured composite bionic tool was proposed. Under the same cutting parameters and conditions, the temperature rise and cutting force can be suppressed, and the tool stability can be reduced. Firstly, the design tool was modeled in three dimensions and the optimal bionic tool structure was optimized by finite element simulation technology. Secondly, four microstructures were constructed on the basis of biomimetic tools, and the optimum microstructures were selected based on shear force, stress distribution and chip discharge capacity. The smallest microstructure size parameters were obtained by changing the spacing of microstructures. Finally, on the basis of optimizing the micro-textured biomimetic tool, the surface of the tool was coated, and the influence of coating material on tool performance was discussed. The results showed that the cutting fracture rate of the material increased and the cutting accumulation phenomenon was alleviated obviously when the 45° chute micro-textured bionic tool with composite coating was used for machining. The cutting stability of the tool was enhanced and chip adhesion was reduced when cutting forces and cutting temperatures were reduced. At the same time, compared with conventional tools, the main cutting force and radial force decreased by 35% and 62%, and the cutting temperature decreased by 3.5%. With the decrease in cutting force and cutting temperature, the stability of cutting was enhanced and the phenomenon of chip adhesion on the tool surface was reduced. [ABSTRACT FROM AUTHOR]

Aluminum 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, 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 aluminum 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. [ABSTRACT FROM AUTHOR]