Sustainable machining of aluminum MMCs: The role of biomimetic textured cutting tools in cryogenic conditions

This study evaluated the feasibility of laser-textured biomimetic designs for cutting tools to investigate the effects of laser-textured tools combined with cryogenic cooling using liquid nitrogen (LN2) on the tool-chip interface, built-up edge (BUE) formation, and friction during Al-MMC machining. This study involved selecting a biomimetic design, converting it into a textured cutting tool, evaluating the coefficient of friction (CoF) and cutting forces on the textured surface under dry conditions, and using cryogenic LN2 as a coolant with the textured tool. Femtosecond lasers were used to precisely create biomimetic surfaces near the rake face edge without compromising tool integrity. The pin-on-disc method revealed no significant CoF difference between plain and textured tools or among textured tools within the determinate pin load impact. Dry machining tests showed a higher CoF than the pin-on-disc method owing to strong workpiece material adhesion. Cutting force analysis under dry and textured conditions showed negligible effects on aggregate force components, although textured tools had a higher feed force than untextured ones. Cryogenic cooling with plain tools reduced BUE height, TCClength, and TCCarea compared to dry conditions. Textured tools in dry conditions increased BUE height and acted as chip breakers, reducing TCClength and TCCarea compared to dry plain tools. Most textured tools with cryogenic cooling reduced the BUE height, TCClength, and TCCarea compared to their dry-textured counterparts. The findings suggest that combining biomimetic textured cutting tools with cryogenic machining is a promising approach for sustainable manufacturing of Al-MMC's.