Effect of WEDM surface texturing on Al2O3/TiCN composite ceramic tools in dry cutting of hardened steel

Micro scale textures were fabricated on the rake surface of Al2O3/TiCN composite ceramic cutting tools using WEDM process. The cutting performance of ceramic cutting tools with plain and textured rake surfaces was investigated in the dry cutting of hardened AISI 52100 steel (62 HRC). The performance of cutting tools was evaluated by chip-tool contact length, tool wear, machining forces, cutting temperature, frictional coefficient and chip morphology. Further, a 3D finite element model has been used to study the temperature and stress distribution in the cutting tools. Application of textures obstructing the chip flow direction resulted in uniform stress distribution, and higher groove sliding area ensured maximum reduction of machining forces, material adhesion, cutting and tool temperature. However, the textures parallel to the chip flow direction resulted in bending and curling of chips on the rake face causing an increase of chip-tool contact length and material adhesion as compared to the tools with textures obstructing the chip flow resulting in an increase of friction. The textured tool with textures inclined at an angle to the chip flow direction exhibited the best machining performance as compared to other textured cutting tools. Moreover, this tool exhibited superior anti-adhesion behavior as compared to the conventional cutting tool owing to the reduced chip-tool contact length and area, friction and chip flow angle.