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EASYTOCUTBECAUSEOFTHEIRLOWHARDNESS,BUTTHISADVANTAGEISSOMETIMESCOUNTEREDINCERTAINAPPLICATIONSBYTHEIRLOWMELTINGPOINTANDHIGHDUCTILITY,WHICHCAUSEALUMINUMCHIPSTOADHERETOTHECUTTINGEDGESOFTOOLS,LEADINGTOTOOLFAILURE1MANYDIFFERENTPARAMETERSOFCUTTINGTOOLSHAVEBEENIMPROVED,SUCHASGEOMETRY,SURFACECOATING2,ANDFINISHINGFOREXAMPLE,DIAMONDLIKECARBONDLCCOATEDTOOLSWITHEXTREMELYLOWFRICTIONAREBEINGAPPLIEDINTHEDRYORNEARDRYCUTTINGOFALUMINUMALLOYS3,BUTAFLOODEDCUTTINGFLUIDISREQUIREDINPRACTICALUSETOAVOIDADHERENCEOFALUMINUMCHIPSTODLCCOATEDTOOLS4FURTHER,TOOLBREAKAGEOCCURSFREQUENTLYINCUTTINGPROCESSESSUCHASDEEPHOLEDRILLING,MILLING,ANDTAPPING,INWHICHITISDIFFICULTTODIRECTLYSUPPLYCUTTINGFLUIDTOTHECUTTINGPOINT21CUTTINGTOOLSWITHMICROTEXTUREDSURFACESFIG1SHOWSBOTHASCHEMATICILLUSTRATIONANDASCANNINGELECTRONMICROSCOPESEMHITACHIHIGHTECHNOLOGIESCORP,S3400NXIMAGEOFACUTTINGTOOLWITHAMICROTEXTUREDSEGMENTEDDLCCOATING7WEPREPAREDTHETOOLBASEDON8FIRST,DLCFILMWASUNIFORMLYCOATEDONTHERAKEFACEOFACEMENTEDCARBIDETOOLSUMITOMOELECTRICHARDMETALCORP,SEKN42MBYTHEPLASMAENHANCEDCHEMICALVAPORDEPOSITIONCVDMETHODNEXT,ATUNGSTENMESHWIREWASSETABOVETHECOATEDTOOLFACETOSERVEASAMASKTOCREATEAGRIDASECONDLAYEROFDLCWASTHENCOATEDBYTHECVDMETHOD,RESULTINGINADLCFILMWITHSEGMENTSIZE150MMC2150MMANDCUTTINGCONDITIONSEMULSIONTYPECUTTINGFLUIDNEOSCO,LTD,FINECUTCFS100WASSUPPLIEDATAFLOWRATEOF126L/MINACIRPANNALSMANUFACTURINGTECHNOLOGY592010597600COMPOSIADVANSREADLASECONTENTSLISTSAVAILABLEATSCIENCEDIRECTCIRPANNALSMANUFACTURINGEINTHISSTUDY,WEEVALUATEDTHEANTIADHESIVEEFFECTOFTHEMICROTEXTUREDSURFACEANDDEVELOPEDTECHNIQUESTOIMPROVETHEENGINEERINGAPPROACH,NAMELY,AFUNCTIONALIZATIONOFTOOLSURFACESBYTEXTURES5,6WEDEVELOPEDAMICROTEXTUREDCUTTINGTOOLTODETERMINETHEROLEOFTHETEXTUREDTOOLRAKEFACEINRETAININGCUTTINGFLUID7,REVEALINGTHATTHESURFACESIGNIFICANTLYIMPROVEDLUBRICITYASINDICATEDBYTHEEVALUATIONOFTHESHEARANGLE,THECUTTINGFORCES,ANDTHECOEFFICIENTOFFRICTIONOFTHETOOLRAKEFACETHETOOLCHIPADHESIONHASNOTYETBEENINVESTIGATED22CUTTINGEXPERIMENTPROCEDURESCUTTINGEXPERIMENTSWERECONDUCTEDONALUMINUMALLOYA5052USINGAVERTICALMACHININGCENTERYAMAZAKIMAZAKCORP,AJV18THEEXPERIMENTALSETUPISILLUSTRATEDINFIG2FIG3SHOWSTHEGEOMETRYOFTHECUTTINGTOOLWITHASINGLEINSERTTHECENTEROFTHECUTTERWASSETONTHECENTERLINEOFTHEWORKPIECETABLE1LISTSTHETOSOLVETHEPROBLEMSDESCRIBEDABOVE,WEADOPTEDASURFACE08MMDEEPGRIDGROOVESSPACEDAT80MMIMPROVINGANTIADHESIVEPROPERTIESOFCUTTINANO/MICROTEXTURESTENOMOTO,TSUGIHARADEPARTMENTOFMECHANICALENGINEERING,GRADUATESCHOOLOFENGINEERING,OSAKAUNIVERSITY,SUBMITTEDBYTMATSUO1,OSAKA,JAPAN1INTRODUCTIONALUMINUMALLOYSPROVIDESEVERALADVANTAGES,INCLUDINGAHIGHSTRENGTHTOMASSRATIOANDHIGHCORROSIONRESISTANCEHENCE,THEDEMANDFORALUMINUMALLOYSHASRAPIDLYINCREASED,ESPECIALLYINTHETRANSPORTINDUSTRYCOMPAREDTOSTEEL,ALUMINUMALLOYSAREARTICLEINFOKEYWORDSCUTTINGTOOLSURFACETEXTUREABSTRACTDEMANDFORALUMINUMALLOYDEMANDISDUETOSUCHKEYHOWEVER,ALUMINUMCHIPBREAKAGETOADDRESSTHISPROBLEMFORMEDUSINGFEMTOSECONDTHETEXTUREDSURFACESIGNIFICANTINTERFACEJOURNALHOMEPAGEHTTP/EESEFFECTUSINGMOREREFINEDSURFACETEXTURESONTHEBASISOFOURFINDINGS,WEDEVELOPEDACUTTINGTOOLWITHANANO/MICROTEXTUREDCORRESPONDINGAUTHOR00078506/SEEFRONTMATTERC2232010CIRPDOI101016/JCIRP201003130NGTOOLSURFACESBY21YAMADAOKA,SUITA,OSAKA5650871,JAPANSURFACETOIMPROVETHEDESIREDANTIADHESIVEEFFECTWEALSOEVALUATEDTHECORRESPONDINGCUTTINGPERFORMANCE2MICROTEXTUREDCUTTINGTOOLSURFACESTESHASRAPIDLYINCREASED,ESPECIALLYINTHETRANSPORTINDUSTRYTHISTAGESASAHIGHSTRENGTHTOMASSRATIOANDHIGHCORROSIONRESISTANCEILYADHERETOTHECUTTINGEDGEOFTHETOOLUSED,OFTENLEADINGTOTOOL,WEHAVEDEVELOPEDCUTTINGTOOLSWITHNANO/MICROTEXTUREDSURFACESRTECHNOLOGYFACEMILLINGEXPERIMENTSONALUMINUMALLOYSSHOWEDTHATLYIMPROVESTHELUBRICITYANDANTIADHESIVEPROPERTIESATTHETOOLCHIPC2232010CIRPTECHNOLOGYLSEVIERCOM/CIRP/DEFAULTASPDYNAMOMETERKISTLERCO,LTD,9257BWASSETUNDERTHEWORKPIECETOMEASURETHREECOMPONENTSOFTHECUTTINGFORCESAFTERCUTTINGFOR900M,THERAKEFACEOFTHECUTTINGTOOLWASOBSERVEDTOEVALUATETOOLSURFACEADHESIONTHESEMIMAGEFIG4CONFIRMEDTHATCHIPADHESIONOCCURREDONTHETOOLRAKEFACEAND,MORESPECIFICALLY,THEGROOVESWEREBURIEDBYTHEADHESIONNEAR800NM,PULSEWIDTH150FS,CYCLICFREQUENCY1KHZ,PULSEENERGY300MJASSHOWNINFIG5,THENANO/MICROGROOVESFORMASSINEWAVES,WHICHISTHOUGHTTOMINIMIZETHECONTACTBETWEENTHETOOLSURFACEANDCHIPBEFORELASERIRRADIATION,THERAKEFACEOFTHECUTTINGTOOLWASPOLISHEDWITHDIAMONDSLURRYTOASURFACEROUGHNESSOF40NMPEAKTOVALLEYFIG3GEOMETRYOFTHECUTTINGTOOLTENOMOTO,TSUGIHARA/CIRPANNALSMANUFACTURINGTECHNOLOGY592010597600598THECUTTINGEDGETHETHEORETICALTOOLCHIPCONTACTLENGTHWASCALCULATEDTOBEAPPROXIMATELY180MM,INDICATINGTHATTHESEGMENTSWERELARGEENOUGH150MMC2150MMATTHETOOLCHIPCONTACTTHEGROOVESWERESOWIDETHATCHIPMATERIALEASILYENTEREDINTOTHEGROOVESANDCLOGGEDTHEMUP3CUTTINGTOOLSWITHNANO/MICROTEXTUREDSURFACESTAKINGINTOACCOUNTTHEABOVEMENTIONEDRESULTS,WEDESIGNEDNEWTEXTURESOFCUTTINGTOOLSURFACESTOSERVETWOPURPOSES1TOIMPROVELUBRICATIONBYRETAININGENOUGHFLUIDANDASTABLEFLUIDFILMBETWEENTOOLANDCHIPAND2TOREDUCEFRICTIONBYDECREASINGTHECONTACTAREABETWEENTOOLSURFACEANDCHIPTHENNANO/MICROGROOVESWERENEWLYINTRODUCEDTOTHECUTTINGTOOLSURFACETOACHIEVETHESEPURPOSESLASERINDUCEDPERIODICSURFACESTRUCTURINGTECHNOLOGYWASUSEDTOGENERATENANO/MICROGROOVES9,10ONTHERAKEFACEOFTHECUTTINGTOOLSIRRADIATIONOFLINEARLYPOLARIZEDFEMTOSECONDLASERFIG1PREVIOUSLYDEVELOPEDCUTTINGTOOLWITHMICROTEXTUREDSURFACEUPPERSCHEMATICILLUSTRATIONLOWERSEMIMAGE7PULSESONASURFACEINDUCESINTERFERENCEBETWEENTHEINCIDENTLASERPULSESANDSURFACESCATTEREDLIGHTORPLASMAWAVESFROMDEFECTSORPARTICLESONTHESURFACEPRECISEREGULARGROOVESARESELFORGANIZEDBYADJUSTINGTHELASERENERGYATALOWFLUENCETHATISSLIGHTLYABOVETHEABLATIONTHRESHOLD,WITHTHESPACINGOFREGULARSTRUCTURESEITHERTHESAMEASORSMALLERTHANTHELASERWAVELENGTHAPPLYINGTHISTECHNOLOGY,REGULARNANO/MICROGROOVES100150NMDEEPAND700NMAPARTWEREPRODUCEDONTHERAKEFACEOFTHECUTTINGTOOLSUSINGATITANIUMSAPPHIREBASEDLASERSYSTEMCANONMACHINERYINC,MODELSURFBEATRPEAKWAVELENGTHFIG2EXPERIMENTALSETUPOFFACEMILLINGTESTSPRELIMINARYCUTTINGEXPERIMENTSINVOLVINGBOTHACUTTINGTOOLWITHAPOLISHEDSURFACEANDACUTTINGTOOLWITHGROOVESPARALLELTOTHECUTTINGEDGEWERECONDUCTEDUSINGTHECUTTINGCONDITIONSLISTEDINTABLE1CHIPSADHEREDTOTHERAKEFACEOFTHETEXTUREDCUTTINGTOOLINAWAYSIMILARTOTHATOFTHEPOLISHEDTOOLFIG6,SHOWINGTHATTHEANTIADHESIVEEFFECTWASNOTSUFFICIENTLYPROMOTEDWHENONLYMODIFYINGTHESURFACETEXTURETHEN,AFTERCREATINGTHEGROOVES,DLCFILMWASCOATEDBYARCIONPLATINGONTHECUTTINGTOOLSURFACETOIMPROVEANTIADHESIVENESSTHECOATINGDECREASEDTHEGROOVEDEPTHBY10NMORLESS4CUTTINGTOOLPERFORMANCE41EVALUATIONOFANTIADHESIONTHREETYPESOFCUTTINGTOOLSWEREEVALUATED1THEDLCCOATEDTOOLWITHGROOVESPARALLELTOTHECUTTINGEDGEPARALLELGROOVETOOL2THEDLCCOATEDTOOLWITHGROOVESORTHOGONALTOTHECUTTINGEDGEORTHOGONALGROOVETOOLAND3THECONVENTIONALDLCCOATEDTOOLWITHAPOLISHEDSURFACEPOLISHEDTOOLASSHOWNINFIG7,CUTTINGPERFORMANCEWASEVALUATEDUSINGSEMANDENERGYDISPERSIVEXRAYSPECTROMETRYEDXANALYSISOFTHERAKEFACEOFTHECUTTINGTOOLSAFTERCUTTINGFOR1800MFIG8SHOWSAGRAPHOFTHEALUMINUMATOMCONCENTRATIONONTHETOOLRAKEFACE,QUANTITATIVELYMEASUREDINANEDXALIMAGEFROMFIGS6AND7,WEFOUNDTHATDLCCOATINGDECREASEDALUMINUMADHESIONFIGS7AND8CONFIRMTHATTHETOOLSURFACEWITHANANO/MICROTEXTURE,PARTICULARLYNANO/MICROGROOVESPARALLELTOTHEMAINCUTTINGEDGE,HADANEXCELLENTANTIADHESIVEPROPERTYMORESPECIFICALLY,THEADHESIONAREAISREDUCEDTOONETHIRDORLESSOFTHATEXPERIENCEDWITHTHEPOLISHEDTOOLTABLE1CUTTINGCONDITIONSWORKPIECEA5052W75MML210MMFURUKAWASKYALUMINUMCORPTOOLCEMENTEDCARBIDESUMITOMOELECTRICHARDMETALCORP,SEKN42MTOOLGEOMETRYAXIALRAKEANGLE,UA208RADIALRAKEANGLE,URC038TRUERAKEANGLE,A1248CORNERANGLE,G458CUTTERDIAMETER,D80MMCUTTINGSPEED380M/MINDEPTHOFCUT3MMFEEDRATE012MM/REVCUTTINGLENGTH180MC25,10PASSESCUTTINGFLUIDEMULSIONTYPENEOSCO,LTD,FINECUTCFS100SUPPLYRATE126L/MINTHEINFLUENCEOFTHENANO/MICROGROOVEDIRECTIONONINCREASINGANTIADHESIONMAYBEDESCRIBEDASFOLLOWSINTHECASEOFTHEORTHOGONALGROOVETOOL,CHIPSFLOWINGOVERTHERAKEFACEOFTHETOOLAREALWAYSINCONTACTWITHTHEFACE,INCREASINGCHIPADHESIONANDCAUSINGTHEBREAKDOWNOFCUTTINGFLUIDFILMONTHETOOLCHIPINTERFACEINTHECASEOFTHEPARALLELGROOVETOOL,CHIPSCOMEINCONTACTINTERMITTENTLYWITHTHERAKEFACEOFTHETOOL,AVOIDINGCHIPADHESIONANDSUPPLYINGCUTTINGFLUIDFROMTHEVALLEYSOFTHEGROOVESTOTHETOOLCHIPINTERFACETHETOOLSURFACEWASOBSERVEDUSINGANOPTICALMICROSCOPEKEYENCECORP,VF7500EVERY180MOFTHETOTALCUTTINGDISTANCETOEVALUATECHANGESINADHESIONASCUTTINGPROGRESSEDFIG9SHOWSCHANGESINTHEALUMINUMADHESIONAREA,CALCULATEDBYIMAGEANALYSISOFTHEMICROPHOTOGRAPHADHESIONAREASINCREASEDONLYSLIGHTLYINTHENEWLYDEVELOPEDTOOLSINPARTICULAR,THEPARALLELGROOVETOOLGREWAPPROXIMATELYONEEIGHTHTHEAREAASCOMPAREDTOTHEPOLISHEDTOOLMEASUREMENTOFTHESECTIONALPROFILEOFTHETOOLRAKEFACEINTHEORTHOGONALDIRECTIONTOTHECUTTINGEDGEWERECARRIEDOUTAFTERCUTTINGFOR1800MTOEVALUATEBUILDUPONTHEEDGEASSHOWNINFINALLY,AHIGHMAGNIFICATIONSEMOBSERVATIONWASPERFORMEDTODETERMINEADHESIONTOTHETOOLSURFACEINDETAILFIG11FROMTHISFIGURE,WECONFIRMEDTHATNANO/MICROGROOVESWERENOTFIG4CUTTINGTOOLWITHMICROTEXTUREDSURFACEAFTERCUTTINGFOR900MFIG7RAKEFACEOFCUTTINGTOOLAFTERCUTTINGLEFTSEMIMAGERIGHTEDXALIMAGEFIG8CONCENTRATIONOFALUMINUMATOMONTHERAKEFACEOFCUTTINGTOOLTENOMOTO,TSUGIHARA/CIRPANNALSMANUFACTURINGTECHNOLOGY592010597600599FIG10,ABUILDUPEDGEOF05MMHIGHWASGENERATEDONTHERAKEFACEOFTHEPOLISHEDTOOL,WHEREASITWASNEGLIGIBLEONTHERAKEFACESOFTHEDEVELOPEDTOOLSFIG5NEWLYDEVELOPEDCUTTINGTOOLWITHNANO/MICROTEXTUREDSURFACEFIG6SEMIMAGESOFRAKEFACEOFNONCOATEDCUTTINGTOOLSAFTERCUTTINGFOR900MBURIEDBYADHESIONAFTERCUTTINGFOR1800M42EVALUATIONOFTOOLSURFACELUBRICITYTHECUTTINGSHEARANGLEANDCUTTINGFORCEWEREEVALUATEDTODETERMINETHEIRIMPACTONCUTTINGPERFORMANCEITISWELLKNOWNTHATTHESHEARANGLEINCREASESASFRICTIONONTHERAKEFACEDECREASESSHEARANGLEFWASCALCULATEDAFTERAPPROXIMATINGTHREEDIMENSIONALCUTTINGTOTWODIMENSIONALCUTTINGTHEFOLLOWINGEQUATIONFIG9CHANGESINADHESIONAREAONRAKEFACEWITHCUTTINGDISTANCETENOMOTO,TSUGIHARA/CIRPANNALSMANUFACTURINGTECHNOLOGY592010597600600FIG10SECTIONALPROFILEOFRAKEFACEOFCUTTINGTOOLAFTERCUTTINGISVALIDFORTWODIMENSIONALCUTTING11FTANC01RCCOSA1C0RCSINAC20C21RCHHC1WHERERCISTHECUTTINGRATIO,HISTHEUNDERFORMEDCHIPTHICKNESS,HCISTHECHIPTHICKNESS,ANDAISTHETRUERAKEANGLEHWASCALCULATEDGEOMETRICALLY,ANDHCWASMEASUREDUSINGAMICROMETERAT2MMINTERVALSTHESHEARANGLEOBTAINEDBYT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）；（2）的类金刚石涂层刀具沟槽垂直于切削刃（正交槽工具）；（3）传统的金刚石涂层工具与抛光表面（抛光工具），如图7所示，切割1800米后使用扫描电子显微镜和能量色散X射线光谱（能谱）分析前刀面切割工具和对性能进行了评价。图8显示图形为前刀面上铝原子浓度，定量衡量一个EDXAL图像。湘潭大学兴湘学院本科生毕业设计（论文）7图7。切削刀具切割后前刀面（左扫描电镜图像；右EDXAL图像）图8切削刀具前刀面上的铝原子湘潭大学兴湘学院本科生毕业设计（论文）8从图6和7，我们发现，类金刚石涂层铝附着力降低。图7和8证明，刀具表面纳米/微有很好的防粘性能，特别是纳米/微沟槽平行的主切削刃。更具体地