Performance and reliability of Al2O3/TiC ceramic tool with multi-bionic surface microstructure in intermittent dry turning of AISI 52100 hardened steel

The biological structures of Odontodactylus scyllarus, Gampsocleis grafiosa and Procambarus clarkia have interesting functions. They provide valuable inspiration for creating multi-bionic surface microstructure on Al2O3/TiC cutting tool. The microstructure is expected to effectively improve performance and reliability. This work analyzed performance and reliability of Al2O3/TiC cutting tool with multi-bionic microstructure in intermittent dry turning of AISI 52100 hardened steel. It was found that the dimension and the shape of the multi-bionic surface microstructure were greatly affected by the heat source intensity of the laser pulse. The cumulative damage Dcm of tool was negatively correlated with the fractal dimension Fmca obtained for laser-caused microscopic crack. The correlation coefficient was found to be -0.8635. On the contrary, the fracture toughness KICM was positively correlated with Fmca. The correlation coefficient had a value of 0.8731. A theoretical performance metric Pm was put forward for the tool by fusing tool stress, material damage and fracture toughness. The theoretical performance metric Pm was verified by the experimental tool life. Both tool performance and tool reliability were enhanced by using the proposed surface microstructure. Moreover, the optimum tool performance and the highest tool reliability arose simultaneously when the laser angle was 75°. Tool performance and tool reliability can be separately enhanced by 57% and 63% at this laser angle.