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<p>Built-up edge (BUE) formation is a detrimental phenomenon in machining processes, which is caused by the adhesion and accumulation of workpiece material on the cutting tool’s edge. The phenomenon is govern by a localized welding mechanism between the chip and the cutting edge, leading to accelerated tool wear and reduced machining efficiency. Graphene oxide, acting as a nano-lubricant, minimizes tool wear by reducing friction and dissipating heat owing to its exceptional thermal conductivity. The current study investigated the application of graphene oxide nanomaterial as a coating for carbide cutting inserts to suppress BUE formation during the machining of aluminum alloy 7075. As a preliminary step, the mechanism of BUE and built-up layer (BUL) formation on the cutting tool was initially analyzed using field emission scanning electron microscopy (FE-SEM) imaging. Initial experiments identified critical factors influencing BUE formation, including cutting speed thresholds. Specifically, BUE formation occurred at cutting speeds below 112.025&#xa0;m/min and was absent at higher speeds. At extremely low speeds (3.534&#xa0;m/min), BUE formation was prominent, with its magnitude increasing as the speed rose to 19.725&#xa0;m/min. Controlled experiments with graphene oxide-coated tools demonstrated significant surface temperature and friction reductions, as validated through thermal imaging. Standalone Backscattered Electron (BSE) imaging and Energy-Dispersive X-ray Spectroscopy (EDS) further substantiated that the graphene oxide layer functioned as an effective low-shear sacrificial solid lubricant, significantly mitigating aluminum adhesion and retarding the dynamic fluctuations that drive BUE growth under the investigated cutting regime.</p>

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Mitigating Built-Up Edge through Graphene Oxide Coating in Al7075 Turning

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • Abolfazl Foorginejad,
  • Mojtaba Arabzadeh,
  • Yadollah Yaghoubinezhad,
  • Hossein Afshari

摘要

Built-up edge (BUE) formation is a detrimental phenomenon in machining processes, which is caused by the adhesion and accumulation of workpiece material on the cutting tool’s edge. The phenomenon is govern by a localized welding mechanism between the chip and the cutting edge, leading to accelerated tool wear and reduced machining efficiency. Graphene oxide, acting as a nano-lubricant, minimizes tool wear by reducing friction and dissipating heat owing to its exceptional thermal conductivity. The current study investigated the application of graphene oxide nanomaterial as a coating for carbide cutting inserts to suppress BUE formation during the machining of aluminum alloy 7075. As a preliminary step, the mechanism of BUE and built-up layer (BUL) formation on the cutting tool was initially analyzed using field emission scanning electron microscopy (FE-SEM) imaging. Initial experiments identified critical factors influencing BUE formation, including cutting speed thresholds. Specifically, BUE formation occurred at cutting speeds below 112.025 m/min and was absent at higher speeds. At extremely low speeds (3.534 m/min), BUE formation was prominent, with its magnitude increasing as the speed rose to 19.725 m/min. Controlled experiments with graphene oxide-coated tools demonstrated significant surface temperature and friction reductions, as validated through thermal imaging. Standalone Backscattered Electron (BSE) imaging and Energy-Dispersive X-ray Spectroscopy (EDS) further substantiated that the graphene oxide layer functioned as an effective low-shear sacrificial solid lubricant, significantly mitigating aluminum adhesion and retarding the dynamic fluctuations that drive BUE growth under the investigated cutting regime.