Bionic Design and Performance Evaluation of Micro-Textural Patterns on Cutting Tools

Surface engineering of micro-scale nanocomposite coatings on metal cutting tools enhances retention of hardness at high temperatures. This study aimed to impart wear resistance for the cutting tools while increasing cutting power and reducing the coefficient of friction, especially for machining hard-to-cut materials like D2 tool steels. This investigation examined the influence of laser surface modification with thin film bionic micro textures and tungsten deposition on the rake surface of the tungsten carbide uncoated cutting tools to reduce friction and wear. This study describes a unique material texturing method inspired by the surface morphology of dung beetle bionic zigzag patterns engineered on the substrates of cutting tools. In the dry cutting trials, an improvement in the machining performance and service life of the cutting tools was observed, which was attributed to the synergistic effect of surface textures and modification of the chemical composition of the rake surface of the cutting tools. The combined features of the dimple and mesh pattern provide a robust surface with high hardness, improved wear resistance, and the potential for reduced friction. A 24.47% decrease in the coefficient of friction was observed after the computer numerical control machining of textured inserts, leading to a reduction in tool wear and an increase in tool life. The technique helps to tailor surface characteristics for various metal-cutting tools and can also be extended for surface modification of mechanical implements in agricultural applications.