Title: Experimental comparative study of conventional, micro-textured and coated micro-textured tools during machining of hardened AISI 1040 alloy steel

Authors: Kishor Kumar Gajrani; Rokkham Pavan Kumar Reddy; M. Ravi Sankar

Addresses: Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati – 781039, India ' Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati – 781039, India ' Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati – 781039, India

Abstract: To minimise harmful effects of cutting fluids in machining, researchers have shown interest in the field of dry machining. Surface texturing has capacity to affect tribological conditions. Few researchers have tried to apply controlled surface texturing on cutting tools. In the current research work, micro-textures were fabricated on the rake face of cutting tool using mechanical indentation method. The experimental study explains about advantages of micro-textured and micro-textured with MoS₂ coated tools compared to conventional tools. To find out the effect of micro-textures on the strength and rigidity of cutting tool, structural analysis was carried out. Negligible differences over generated von Mises stresses and strains were noticed due to presence of micro-textures on cutting tools. Dry cutting tests were performed and results show significant reduction of cutting forces, feed forces and friction coefficient by micro-textured and coated micro-textured cutting tools compared to conventional tool. Chip morphology with different tools is also studied.

Keywords: surface texturing; surface modification; micro-texture; cutting tools; mechanical indentation; dry cutting; MoS2; solid lubricant; molybdenum disulphide; chip morphology; micro-textured tools; hardened AISI 1040; alloy steels; dry machining; rake face; tool strength; tool rigidity; tool coatings; stress; strain; cutting forces; feed forces; friction coefficient.

DOI: 10.1504/IJMMM.2016.078982

International Journal of Machining and Machinability of Materials, 2016 Vol.18 No.5/6, pp.522 - 539

Received: 20 May 2015
Accepted: 19 Nov 2015
Published online: 08 Sep 2016 *

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