Study on the Effects of Micro-Groove Tools on Surface Quality and Chip Characteristics When Machining AISI 201

The excellent mechanical properties of AISI 201 make it well-suited for applications in industrial components, transportation, and household appliances. However, during machining, this material generates high cutting forces and temperatures, leading to rapid tool wear and high costs. To address this issue, micro-grooves were designed on the rake face in areas prone to thermal and mechanical stress concentration. Through machining experiments focusing on workpiece surface quality, it was found that micro-grooved tools produced superior surface quality, specifically manifested in lower surface roughness, reduced work hardening, and shallower hardened layer depth. Experiments demonstrate that under identical conditions, increasing the cutting speed with tool M reduces the workpiece surface roughness by 0.096 μm to 0.236 μm compared to tool O. Under identical conditions, increasing the feed rate with tool M reduces the workpiece surface roughness by 0.070 μm to 0.236 μm compared to tool O. As cutting speed varies, the absolute surface hardness of workpieces machined by tool M decreases by approximately 39.85 HV, representing a hardness reduction of 14.5%. As feed rate varies, the surface hardness of workpieces machined with tool M is suppressed to a level 10.2%–14.2% lower than that of tool O. As cutting depth varies, the surface hardness of workpieces machined with tool M is suppressed to a level 10.0%–14.7% lower than that of tool O. Additionally, micro-grooved tools demonstrated superior chip curling and breaking performance. This tool design approach, optimized for tool durability and workpiece surface quality, establishes a research foundation for tool design targeting difficult-to-machine materials.