Numerical investigation of the performance of microbump textured cutting tool in dry machining of AISI 1045 steel

• FEM is used to investigate effects of microbumped tools on machining of mild steel.
• Microbumps on the rake face of a cutting tool are effective in reducing cutting forces.
• Minimum cutting force may be realized around two width values at 20 and 400 μm.
• It is noted that an optimal edge distance value may exist between 320 and 420 μm.
• An optimal microbump width to height ratio exists to minimize the cutting force.

This paper investigates the performance of microbump textured cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using AdvantEdge finite element simulation. Microbumps are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microbump textured tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microbump parameters are examined: microbump width, microbump height, and edge distance (the distance from cutting edge to the first microbump). Their effects are assessed in terms of the main force, thrust force, and chip–tool contact length. It is found that microbump textured cutting tools generate lower cutting force and thrust force and consequently lower the energy consumption for machining. The micobump width, microbump height, and edge distance all have influence on cutting force in their own ways.