Micro-texture at the coated tool face for high performance cutting

This paper describes the effect of micro surface texture on the lubrication conditions at the tool rake face in machining aluminum alloy. For this purpose, four types of micro surface texture were fabricated at the tool faces of cemented carbide through spattering, photolithography and wet etching, and the micro-textured tool faces were coated with diamond like carbon (DLC) or TiN. Then, orthogonal cutting experiments of aluminum alloy were conducted using the coated tools with and without micro-texture. The normal and friction forces and the coefficient of friction were obtained from the measured cutting forces. In addition, tool surface conditions were inspected with a CCD microscope after machining. As a result, it was found that parallel type and square-dot type of micro-textures improved effectively the lubrication conditions in machining aluminum alloy A6061-T6. It was also found that micro-texture was likely to improve the lubrication conditions more effectively as the pattern of texture became smaller and deeper. ► Tool inserts with different micro- textured face were fabricated by photolithography. ► Particular types of micro-textured face decreased the friction cutting force. ► Smaller and deeper micro texture was more effective.