On-machine Tool Resharpening for Dry Machining of Aluminum Alloys

The present study proposes a novel strategy for removing the adhesion layer from the tool surface and recovering the cutting tool performance without detaching the cutting tool from the machine tool; namely, an on-machine tool resharpening process, in order to address the issues related to the dry machining of aluminum alloys. A series of experiments clearly showed that the developed strategy employing the phenomenon of liquid metal embrittlement (LME) successfully removes the aluminum adhesion from the tool surface without damage to the tool substrate, and the resharpened tool shows excellent cutting performance nearly equivalent to its virgin state.