Research on cutting performance of micro-texturing tools for cutting aluminum alloys

To address the common issues of high cutting forces, poor surface quality, and chip wrapping in aluminium alloy machining, this study innovatively designed two types of micro-groove textures on the tool surface based on the natural flow direction of chips: one parallel to and the other perpendicular to the main cutting edge (micro-texture width: 50 µm, micro-texture depth: 50 µm, micro-texture edge distance (distance from the main cutting edge): 200 µm, micro-texture spacing: 200 µm). At a cutting speed of 1250 r/min, a feed rate of 0.15 mm/r, and a cutting depth of 0.1 mm, Through finite element simulation analysis of cutting force, temperature, stress, and chip morphology, and using laser processing technology to precisely prepare micro-textured tools for actual cutting experiments, the study systematically evaluated the impact of microtextures on performance. Furthermore, this study integrated composite solid lubricants into the microgrooves to develop self-lubricating tools and investigated the synergistic effects of cutting speed and lubrication conditions on the performance of micro-textured tools. The results showed that micro-textured tools significantly reduced cutting force, stress, and temperature, improving friction and heat dissipation. Among them, self-lubricating micro-textured tools performed particularly well, further reducing cutting force (with a maximum reduction of 20.39%), improving surface quality (roughness of 1.421 µm), and optimizing chip morphology. The novelty of this study lies in the synergistic optimization of heat dissipation, friction reduction, and chip removal performance through micro-texture orientation design and solid lubricant-assisted machining. This technology provides an effective solution for enhancing the efficiency and quality of aluminium alloy machining.