Additive surface texturing of cutting tools using pulsed laser implantation with hard ceramic particles
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TOOLING
Additive surface texturing of cutting tools using pulsed laser implantation with hard ceramic particles S. Böhm1 · A. Ahsan1 · J. Kröger1 · J. Witte1 Received: 5 June 2020 / Accepted: 6 September 2020 © The Author(s) 2020
Abstract In recent years surface texturing of the cutting tools has proved to improve tribological characteristics at tool/chip and tool/ workpiece interface and help to reduce cutting and feed forces as well as tool wear. Most, if not all, of the studies have focused on subtractively made textures whereby the material is removed from the surface. This study investigates the performance of additively made surface structures whereby hard ceramic particles are dispersed in the form of dome shaped textures on the surface of the cutting tools using solid state millisecond pulsed laser (pulsed laser implantation). Dry cutting tests were performed on ductile cast iron. The results show a greater reduction of process forces with implantation of flank face as compared to rake face. Both cutting and feed forces were reduced by 10% compared to the non-structured tool. In addition, the tool life increased by a factor of 3 whereas the average flank wear reduced by as much as 80% and cutting edge rounding by up to 60%. Keywords Cutting tool · Surface texturing · Laser dispersing · Laser implantation · Surface structuring
1 Introduction In machining processes, the cutting tools are required to possess high surface hardness to slow down abrasive wear rate, good fracture toughness to avoid edge chipping and cracking, thermal stability at cutting temperatures as well as low chemical affinity with the work material. In addition, low friction coefficient is required between the tool and the work material to minimize resistance to material flow and This project (HA Project No. 695/19-15) is funded in the framework of Hessen ModellProjekte, financed with funds of LOEWE – Landes-Offensive zur Entwicklung Wissenschaftlichökonomischer Exzellenz, Förderlinie 3: KMU-Verbundvorhaben (State Offensive for the Development of Scientific and Economic Excellence) * A. Ahsan a.ahsan@uni‑kassel.de S. Böhm s.boehm@uni‑kassel.de J. Kröger j.kroeger@uni‑kassel.de 1
Department of Cutting and Joining Technology (tff), University of Kassel, Kurt‑Wolters‑Str. 3, 34125 Kassel, Germany
overheating at the tool/chip and tool/workpiece interfaces [2, 4]. Thus, minimization of friction during cutting leads to greater tool life, improved surface quality, higher cutting speeds and increased productivity. The industrial practice to improve tribological characteristics includes low-friction coatings [5, 12, 13, 20, 23] and novel lubrication techniques [3, 29, 31, 36].
1.1 Surface texturing by material removal Surface texturing has been shown to be an effective method for improving the tribological behaviour under both fullfilm as well as boundary lubrication conditions for various applications [9, 14]. Advances in ultrashort pulsed lasers (pulse duration times in pico- and femtosecond regions) has led to numerous research studi
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