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Technical Brief

Numerical Investigation of Microtexture Cutting Tool on Hydrodynamic Lubrication

[+] Author and Article Information
Zhengyang Kang

School of Mechanical Engineering,
Jiangsu University,
Jiangsu 212013, China
e-mail: kzy_blue@yeah.net

Yonghong Fu

School of Mechanical Engineering,
Jiangsu University,
Jiangsu 212013, China
e-mail: fyh@ujs.edu.cn

Jinghu Ji

School of Mechanical Engineering,
Jiangsu University,
Jiangsu 212013, China
e-mail: andyjee@163.com

Liang Tian

Chendu Tool Research Institute Co., Ltd.,
Sichuan 212013, China
e-mail: tl825@163.com

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received July 5, 2016; final manuscript received December 13, 2016; published online May 16, 2017. Assoc. Editor: Jordan Liu.

J. Tribol 139(5), 054502 (May 16, 2017) (8 pages) Paper No: TRIB-16-1211; doi: 10.1115/1.4035506 History: Received July 05, 2016; Revised December 13, 2016

The aim of this technical brief is to provide a numerical approach to investigate the lubricity enhancement effect of microgrooves texture on tools' rake face. The key parameters related to cutting condition and grooves morphology were considered in the analytical model of tool–chip friction pair. The fully textured surfaces with the periodic microgrooves were systematically studied by solving the nondimensional Reynolds equation with the multigrid method. The results indicated that the microgrooves texture generates extra carrying capacity comparing to the flat tool and the optimum grooves direction is vertical to the chip sliding. Higher area density and optimum grooves width can further promote hydrodynamic lubrication. By modifying the tool rake face geometry to restrict the tool–chip slope angle, efficiency of surface texture could be greatly extended. In addition, the film's average pressure was nearly proportional to the chip velocity. Hence, the textured tool is more effective in high-speed cutting.

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Figures

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Fig. 1

Schematic of penetration mechanism through microgrooves

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Fig. 2

Schematic of tool and chip contact in cutting process

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Fig. 3

Analytical model of tool–chip friction pair in separation region

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Fig. 4

(a) Top view of textured surface and (b) cross section view of microgroove

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Fig. 5

Distributions of dimensionless film thickness and pressure: (a) θ = 0 deg, (b) θ = 45 deg, and (c) θ = 89 deg

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Fig. 6

Dimensionless film thickness and pressure along X-direction at Y = 10, θ = 89 deg: (a) ω = 1.00, (b) ω = 0.75, (c) ω = 0.50, and (d) ω = 0.25

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Fig. 7

Dimensionless average pressure, Pav, versus grooves angle, θ, of larger size grooves

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Fig. 8

Dimensionless average pressure, Pav, versus grooves angle, θ, of smaller size grooves

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Fig. 9

Effect of slope angle, ω, on dimensionless average pressure, Pav, at various grooves depths, Hg

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Fig. 10

Effect of grooves width, wg, on dimensionless average pressure, Pav, at various area densities, Sp

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Fig. 11

Dimensionless film thickness and pressure along X-direction at Y = 10 with specific area density, Sp = 0.2, and various grooves widths: (a) wg = 30 μm, (b) wg = 50 μm, (c) wg = 70 μm, and (d) wg = 90 μm

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Fig. 12

Effect of chip velocity, U on the dimensionless average pressure, Pav, at various slope angles, ω

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