Influence of textures on cutting tool tribology in dry machining of super duplex stainless steel

Abstract Flank face surface texturing has proven to be an effective approach to improve tool wear resistance, yet the impact of texture shape on flank wear remains insufficiently explored. This research examines the performance of dimple-, groove-, and wave-textured flank faces during dry turning of super duplex stainless steel SDSS 2507. Tool performance was assessed through flank wear measurements, SEM–EDX analysis of wear mechanisms, and chip morphology evaluation under different cutting conditions. All textured inserts demonstrated superior wear resistance compared to non-textured tools, with minimum flank wear values of 80 μm, 69 μm, and 65 μm for dimple, groove, and wave-textured tools, respectively, observed at a cutting speed (v c ) of 125 m/min, feed rate (f r ) of 0.12 mm/rev, and depth of cut (d c ) of 0.4 mm. At lower cutting parameters, adhesion-dominated wear prevailed, where dimple-textured tools exhibited slightly lower flank wear, while groove- and wave-textured tools displayed comparable performance. With increasing cutting speed and feed rate, abrasive wear became dominant, and groove- and wave-textured tools outperformed dimple-textured tools probably due to improved debris evacuation, enhanced heat dissipation, and more uniform stress distribution along the flank face. SEM–EDX and chip morphology analyses supported these observations. Taguchi-based S/N ratio analysis identified the wave texture with v c = 125 m/min, f r = 0.12 mm/rev, and d c = 0.4 mm as the optimal parameter combination for the lowest flank wear. The findings highlight the critical role of flank face texture geometry in controlling wear mechanisms and enhancing machining performance for difficult-to-machine materials under dry conditions.