Design and experimental study of biomimetic microtextured hard alloy cutting tools based on sparse matrix and hydrodynamic lubrication theory

Friction between the rake face of the tool and the chip is a primary contributor to tool rake face wear. Hence, reducing the friction coefficient between the tool’s rake face and the chip proves to be an effective method for wear mitigation. To minimize the friction coefficient of cutting tools, distinctive microtextures were laser-engraved onto the rake face, employing hydrodynamic lubrication principles. To minimize the adverse impact of microtextures on the tool and simultaneously achieve hydrodynamic lubrication, a sparse matrix arrangement method was introduced for microtexture placement. For further enhancement of the hydrodynamic lubrication effect, finite element analysis was utilized to optimize both the depth and arrangement of microtextures. Friction and cutting experiments were performed to validate the lubrication efficiency of biomimetic microtextures, with an accompanying analysis of the lubrication mechanism. In summary, biomimetic microtextures successfully diminish friction between the tool’s rake face and the chip, resulting in a significant reduction in three-dimensional cutting forces, notably decreasing the main cutting force and accomplishing the objective of reducing tool wear.