Comparative performance analysis of micro-structured carbide inserts in machining of EN19 alloy steel

Surface structuring has been long existed to improve the tribological application. Recently, it has been applied to the cutting tools and has shown the promising results. However, no study has been yet conducted that identified the suitable shape of structures that can be meritoriously applied to the cutting tool. In this study, laser-radiated micro-structures in shape of holes and slots were created on the rake face of cutting tools. Their machining performance was observed over the range of cutting speed and compared to unstructured cutting tool. Machining factors such as cutting force, compression ratio, contact length and tool wear were selected as a criterion of performance. Wide range of orthogonal cutting experiments was performed to identify shapes of micro-structures that can bring elevated results in mechanical machining. Sticking and sliding contact characterization were executed. For the greater advantage, the assessment of machinability rating has also been taken under consideration. It was found that the end goal (better performance or reduced energy consumption) of mechanical machining process is associated with structure shape.