Cutting performance and wear mechanism of nanoscale and microscale textured Al2O3/TiC ceramic tools in dry cutting of hardened steel

Nanoscale and microscale textures with different geometrical characteristics were fabricated on the surface of the Al2O3/TiC ceramic tool, and molybdenum disulfide (MoS2) solid lubricants were burnished into the textures. The effect of the textures on the cutting performance was investigated using the textured self-lubricated tools and conventional tools in dry cutting tests. The tool wear, cutting force, cutting temperature, friction coefficient, surface roughness and chip topography were measured. Results show that the cutting force, cutting temperature, friction coefficient and tool wear of nanoscale and microscale textured self-lubricated tools are significantly reduced compared with the conventional tool, and the developed tool with wavy microscale textures on the rake face is the most effective in improving the cutting performance. The textured self-lubricated tools increase the surface roughness of machined workpiece, while they can reduce the vibration for a stable cutting and produce more uniform surface quality. The chip topography is changed by the textured self-lubricated tools. As a result, the nanoscale and microscale textured self-lubricated tools effectively improve the cutting performance of conventional Al2O3/TiC ceramic tool, and they are applicable to a stable dry cutting of the hardened steel.