The Design and Application of Variable Distribution Density Micro-Textured Tool

A novel design method of grooved type micro-textured tool(MTT) was presented. The lubrication and cooling state of the contact area between the rake face and the chip were analyzed. Based on the penetration process and heat transfer process of cutting fluid on the rake face, the tool-chip contact area was divided into low temperature zone(LTZ) and high temperature zone(HTZ). The penetration of cutting fluid along the micro-texture(MT) groove and the penetration perpendicular to the groove in the LTZ were modeled. It is found that the size parameters and distribution density of the MT are related to them. The heat transfer process of cutting fluid and tool in HTZ and were modeled and analyzed. The secondary cutting phenomenon in micro-textured HTZ surface was modeled as well. The relationship between secondary cutting and texture size parameters is established, and the criteria for the occurrence of secondary cutting are proposed. Based on the theory above, MTTs with variable distribution density were designed and prepared. The design and theoretical model were verified in turning nickel-based superalloy GH4202.