Assessment of Microgrooved Cutting Tool in Dry Machining of AISI 1045 Steel: A Numerical Study

This paper studies the performance of microgrooved cutting tool in dry orthogonal machining of mild steel (AISI1045 steel) using Finite Element (FE) simulation to gain insights into how to improve performance of cutting tools. Microgrooves are designed on the rake face of tungsten carbide (WC) cutting inserts. The purpose is to test the effect of microgroove textured tools on machining performance and to compare it with non-textured cutting tools. Specifically, the following groove parameters are examined: groove width, groove depth, edge distance (the distance from cutting edge to the first groove). Their effects are assessed in terms of cutting force and thrust force. It is found that microgrooved cutting tools generate lower cutting force and thrust force and consequently lower the energy necessary for machining. The groove width, groove depth, and edge distance have big influence on the cutting force and thrust force. Consequently, this research provides insightful guidance for optimizing cutting tools.