Effect of Derivative Cutting of Flank-Faced Textured Ceramic Tools on Machined Surface

Abstract

Surface microtexturing of the flank faces of tools is a promising way to improve the quality of machined workpiece surfaces. However, microtextures are often clogged in the process of machining because of the derivative cutting. The impact of derivative cutting on machined surface is frequently ignored. In this study, a microtexture was developed on the flank face of an Al₂O₃ ceramic tool, which paralleled to the cutting edge. The influence of derivative cutting on machined surfaces required to be systematically investigated according to surface roughness, surface topography, work hardening, and microstructural analysis. Results showed that derivative cutting occurred at cutting velocities ranging from 90 to 270 m/min, leading to an enhancement in the surface quality. Derivative cutting had an obvious impact on surface roughness, with the cutting velocity increased from 90 to 270 m/min. Furthermore, the bottom edge of the texture as a “cutting edge” can timely replace the main cutting edge of sudden failure, leading to the tool lives extension and surface quality improvement.