Optimization and fabrication of curvilinear micro-grooved cutting tools for sustainable machining based on finite elemen
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ORIGINAL ARTICLE
Optimization and fabrication of curvilinear micro-grooved cutting tools for sustainable machining based on finite element modelling of the cutting process Guoliang Liu 1 & Tuğrul Özel 2 & Jianming Li 3 & Dexiang Wang 1 & Shufeng Sun 1 Received: 28 April 2020 / Accepted: 9 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The benefits of micro-textures on cutting tools have been confirmed widely in implementing sustainable machining. However, the derivative cutting processes induced by the sharp edges of textures weakened the potential benefits. In our preliminary work, the newly designed curvilinear micro-grooved cutting tool has been proved to eliminate derivative cutting processes and implement sustainable machining than non-textured tools by three-dimensional (3D) finite element (FE) simulations. In this paper, the curvilinear microgroove structures were optimized and fabricated to further improve the cutting performance of minimizing specific cutting energy. The results indicated that all the micro-groove parameters, including the width, spacing, depth, and edge distance (the distance from cutting edge to the micro-grooved area), showed obvious influence on specific cutting energy in their own ways. Specific cutting energy of the metal cutting processes can be effectively reduced by the optimal curvilinear micro-grooved cutting tools, although the optimal structures used in rough and finish turning conditions were different. In addition, a new two-step method was developed in this work to prepare curvilinear micro-grooves on carbide tools with femtosecond laser. The optimal curvilinear micro-grooved cutting tools were fabricated and used in cutting experiments, which verified the simulative results. Keywords Sustainable machining . Curvilinear micro-grooves . Specific cutting energy . Femtosecond laser processing . FEM
1 Introduction In modern days, sustainable machining has been the most important trend in machining industrial fields. Adopting sustainable machining processes can help machining companies to obtain financial and environmental benefits, because the sustainable machining techniques have the features of ecofriendly, waste-free, nonlethal, cost-effective, and energy-
* Shufeng Sun [email protected] 1
School of Mechanical & Automotive Engineering, Key Lab of Industrial Fluid Energy Conservation and Pollution Control (Ministry of Education), Qingdao University of Technology, Qingdao 266033, China
2
Manufacturing and Automation Research Laboratory, Department of Industrial and Systems Engineering, Rutgers University, Piscataway, NJ 08854, USA
3
School of Mechanical Engineering, University of Jinan, Jinan 250022, China
efficient [1]. The metal cutting processes are energy-intensive. The mismatch between the constant increase of energy consumption and the shortage of new energy sources in the world had become more and more incisive in recent years [2]. Furthermore, Balogun et al. stated that the production and consumption of energy intensified e
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