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<p>Tool life is an important criterion in machining. Therefore, a new surface texturing technique is applied to the cutting tool's flank face in order to extend the tool life. Two different types of textures, <i>viz</i>. dot textures (DT) and groove textures (GT), are fabricated perpendicular to the cutting edge on the flank face of the ceramic (CR) and coated carbide (CB) tool by micro-electric discharge machining (μ-EDM) process. These textured tools along with non-textured (NT) tools are then utilized for turning of hardened H13 (60 HRC) steel at low-speed and high-speed conditions. The machining performances, i.e., flank wear (VB), surface roughness (R<sub>a</sub>), and cutting temperature (CT), are compared for both coated carbide and the ceramic tool for DT, GT, and NT in the present study. For both coated carbide tool and ceramic tool, DT tool produces less flank wear and surface roughness in comparison to GT and NT tool. Moreover, textured ceramic tool reduces flank wear by 33-40% and surface roughness by 25-30% compared to coated carbide tool. However, temperature reduces by 30% using textured coated carbide tool in comparison to textured ceramic tool. The higher temperature generated at the tool–workpiece interface for the ceramic tool reveals the formation of white layer after the turning operation that increases the micro-hardness at the machined surfaces. The ceramic tool generates mirror finish surfaces compared to the other tools. The coefficient of determination (R<sup>2</sup>) for the responses is found to be more than 90% which signifies that the developed response models are accurate for prediction.</p>

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A Comparative Study of Different Flank Face Textured Coated Carbide and Ceramic Tools during Hard Machining of H13 Steel

  • 期刊论文

  • 发表日期：

    2025年10月17日

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  • Arunabh Choudhury,
  • Deba Kumar Sarma,
  • Souradeep Dutta,
  • Sanjib Kr Rajbongshi

摘要

Tool life is an important criterion in machining. Therefore, a new surface texturing technique is applied to the cutting tool's flank face in order to extend the tool life. Two different types of textures, viz. dot textures (DT) and groove textures (GT), are fabricated perpendicular to the cutting edge on the flank face of the ceramic (CR) and coated carbide (CB) tool by micro-electric discharge machining (μ-EDM) process. These textured tools along with non-textured (NT) tools are then utilized for turning of hardened H13 (60 HRC) steel at low-speed and high-speed conditions. The machining performances, i.e., flank wear (VB), surface roughness (Ra), and cutting temperature (CT), are compared for both coated carbide and the ceramic tool for DT, GT, and NT in the present study. For both coated carbide tool and ceramic tool, DT tool produces less flank wear and surface roughness in comparison to GT and NT tool. Moreover, textured ceramic tool reduces flank wear by 33-40% and surface roughness by 25-30% compared to coated carbide tool. However, temperature reduces by 30% using textured coated carbide tool in comparison to textured ceramic tool. The higher temperature generated at the tool–workpiece interface for the ceramic tool reveals the formation of white layer after the turning operation that increases the micro-hardness at the machined surfaces. The ceramic tool generates mirror finish surfaces compared to the other tools. The coefficient of determination (R2) for the responses is found to be more than 90% which signifies that the developed response models are accurate for prediction.