Effects of surface texture parameters of cutting tools on friction conditions at tool-chip interface during dry machining of AISI 1045 steel

Dry machining is one of the essential steps towards achieving sustainable manufacturing processes. Sustainable dry machining can be further enhanced by using surface textured cutting tools where the micro-capillary networks on cutting tool surfaces are exploited for tribological benefit in the absence of cutting fluids. This paper presents the results of an experimental study in which rake surfaces of uncoated carbide cutting tools are textured at different levels, and orthogonal machining is performed on AISI 1045 steel under dry machining condition. The results show that skewness, kurtosis, and other surface texture parameters on the rake surface significantly influence the machining forces via altering friction conditions at the tool-chip interface. Further, the orientation of the cutting tool's surface texture pattern has a strong effect on the capability of the surface micro-capillary network to allow atmospheric air, which must serve as a lubricant in dry cutting, to access portions of the tool-chip contact zone. (C) 2019 The Authors. Published by Elsevier B. V.