Bionic design and optimization of cutting tools: Applications and processability

Cutting is a fundamental machining method extensively utilized across various fields, including mechanical engineering, agriculture, forestry, biomedical instrumentation, mineral exploration, and extraterrestrial missions. However, during cutting operations, tools are exposed to high temperatures and friction, which result in diminished cutting efficiency, reduced tool life, and compromised workpiece quality. Advances in bionics are gradually mitigating these challenges. Bionic design provides rich, reliable, and efficient prototypes that enhance tool performance while promoting environmentally friendly, harmonious, and sustainable tool development. In the bionic optimization of cutting tools, the selection of appropriate bionic prototypes and models is crucial. However, the complexity and ambiguity inherent in bionic prototype functions impede the development and widespread adoption of bionic tools. This paper initially focuses on the classification of bionic tools, subsequently proposing five categories of bio-inspired design elements and topological models from the perspective of bio-inspired cutting tools. The second section discusses the applications, advantages, and cutting performance of five types of bionic tools, with an emphasis on both the biomimetic optimization of the tool body and non-tool bodies. These tools are designed by emulating the diverse biological characteristics exhibited by various organisms. Additionally, the underlying mechanisms of the five categories of bionic tools, as well as the corresponding optimization strategies, are explored. Finally, this paper summarizes research on bionic tools and analyzes the current opportunities and challenges they face. In summary, compared to traditional tools, bionic tools demonstrate superior performance in energy efficiency, friction reduction, wear resistance, lubrication, extended service life, and multifunctionality. This offers valuable insights for researchers involved in the design and development of cutting tools.