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52nd CIRP Conference on Manufacturing Systems
52nd CIRP Conference on Manufacturing Systems
Influence of rake face texturing on machining performance of carbide tools
Influence of rake28th
faceCIRP
texturing on machining
Design Conference, performance
May 2018, Nantes, France of carbide tools
Damir Grguraš*, Franci Pušavec
A new methodology
University of Ljubljana, Faculty ofto analyze
Damir
Mechanical theLaboratory
Grguraš*,
Engineering, functional
for Machining and
Franci Pušavec physical
(LABOD), architecture
Aškerčeva 6, 1000 Ljubljana, Slovenia of
existingUniversity
* Corresponding products
ofTel.:
author. Ljubljana, for
Faculty an assembly
of Mechanical
+386-1-4771-711; oriented
Engineering,E-mail
fax: +386-1-4771-768. Laboratory product
for Machining
address: family
(LABOD), Aškerčeva
damir.grguras@fs.uni-lj.si identification
6, 1000 Ljubljana, Slovenia

* Corresponding author. Tel.: +386-1-4771-711; fax: +386-1-4771-768. E-mail address: damir.grguras@fs.uni-lj.si

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Abstract
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
Controlled surface texture of cutting tools has potential to reduce cutting forces, tool wear, etc. Even though several different textured cutting
*tools have beenauthor.
Corresponding
Controlled
identified
surface texture
and 3tested
Tel.: +33 87 37in
of cutting 54 machining
30; has
tools E-mail of various
address:
potential
workpiece materials, it is difficult to conclude the most effective surface texture for
topaul.stief@ensam.eu
reduce cutting forces, tool wear, etc. Even though several different textured cutting
machining performance improvement. Therefore, in this paper, 8 carbide tools with different rake face texturing have been tested and evaluated
tools have been identified and tested in machining of various workpiece materials, it is difficult to conclude the most effective surface texture for
over following estimators: (i) cutting force, (ii) chip shape and (iii) surface roughness. Results are showing that texturing of carbide tools can
machining performance improvement. Therefore, in this paper, 8 carbide tools with different rake face texturing have been tested and evaluated
improve machining
over following performance
estimators: if theforce,
(i) cutting orientation of texturing
(ii) chip shape andis(iii)
parallel to the
surface main cutting
roughness. edge.
Results areInshowing
such cases,
thatthe texturing
texturing of form offers
carbide better
tools can
penetration of the cooling-lubrication fluid into the cutting zone and can serve as a micro-reservoir for constant emulsion replenishment. This
Abstract
improve machining performance if the orientation of texturing is parallel to the main cutting edge. In such cases, the texturing form offers better
results in better cooling and lubrication, which reflects on lower cutting force. On the other hand, no major differences in chip shape and surface
penetration of the cooling-lubrication fluid into the cutting zone and can serve as a micro-reservoir for constant emulsion replenishment. This
Inroughness
today’s
results
have been
business
in better cooling
observed between
environment, the trend
and lubrication,
texturing.
towards
which more
reflects onproduct varietyforce.
lower cutting and customization is unbroken.
On the other hand, no majorDue to this development,
differences in chip shape the
andneed of
surface
agile and reconfigurable
roughness production
have been observed betweensystems emerged to cope with various products and product families. To design and optimize production
texturing.
© 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
systems
© 2019 asThewell as to choose
Authors. Published thebyoptimal
Elsevierproduct
Ltd. matches, product analysis methods are needed. Indeed, most of the known methods aim to
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
© 2019 The Authors. Published by Elsevier Ltd. This islevel.
an open accessproduct
article under the however,
CC BY-NC-ND license
analyze a product
This is an open or one
access product family
article under on the physical
the scientific
CC BY-NC-ND licenseDifferent families, may differ
(http://creativecommons.org/licenses/by-nc-nd/3.0/)largely in terms of the number and
Peer-review under responsibility of the
(http://creativecommons.org/licenses/by-nc-nd/3.0/) committee of the 52nd CIRP Conference on Manufacturing Systems.
nature of components.
Peer-review This fact impedes
under responsibility an efficient
of the scientific comparison
committee and choice
of the 52nd of appropriate
CIRP Conference product familySystems.
on Manufacturing combinations for the production
Peer-review
system. A new under responsibility
methodology of the scientific
is proposed to analyze committee of the 52nd
existing products CIRPofConference
in view on Manufacturing
their functional and physical Systems.
architecture. The aim is to cluster
Keywords: rake face texturing; machining performance; carbide tools; productivity
these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable
Keywords: rake faceBased
assembly systems. texturing; machining
on Datum Flowperformance;
Chain, thecarbide tools;
physical productivity
structure of the products is analyzed. Functional subassemblies are identified, and
a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
similarity between product families by providing design support to both,wear
1. Introduction production system
in turning ofplanners
AISI 1045and product
hardened designers. An illustrative
steel. This beneficial
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
1. Introduction effect in
wear of turning
surface of
texturing
AISI was hardened
1045 mainly broughtsteel. by thebeneficial
This grooves
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
Machinability refers to the ease
© 2017 The Authors. Published by Elsevier B.V.
with which a certain material serving
effect of as a micro-reservoir
surface texturing was for constant
mainly broughtliquid
by (oil
the based
grooves
can be machined.
Machinability However,
refers to the machinability
ease with whichcannot
a be
certain measured
material emulsion)
serving
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. asreplenishment
a (Fig.
micro-reservoir 1)
forand consequentially,
constant liquid for
(oil better
based
directly,
can but it is defined
be machined. over
However, following estimators:
machinability cannot be (i) cutting
measured cooling and
emulsion) lubrication. (Fig.
replenishment Reduction in cutting force for
1) and consequentially, andbetter
tool
force, (ii)Assembly;
directly,
Keywords: buttool
it iswear and
defined
Design tool-life,
over
method; Family (iii)
following chip shape(i)and
estimators:
identification (iv)
cutting wear of textured
cooling carbide tools
and lubrication. when turning
Reduction in cuttingAISIforce
316 and
stainless
tool
surface(ii)
force, quality.
tool wearImprovement of these
and tool-life, (iii)estimators
chip shape reflects on
and (iv) steel was
wear also reported
of textured carbideintools
[6]. when
In addition,
turningauthors
AISI 316 pointed out
stainless
improvement
surface quality.in machinability
Improvement ofofthe workpiece
these material,
estimators which
reflects on that the
steel was texture lay angleinaffects
also reported [6]. Inthe effectiveness
addition, authorsofpointed
lubricationout
leads towardsin machinability
improvement higher machining performance
of the workpiece and higher
material, which and tool-chip
that the texturecontact length.
lay angle Some
affects the other studies also
effectiveness showed,
of lubrication
1.productivity.
Introduction To higher
achieve machining
that, in addition to conventional flood of the product range and characteristics manufactured and/or
leads towards performance and higher and tool-chip contact length. Some other studies also showed,
lubrication, different
productivity. To achieve approaches / strategies
that, in addition have been flood
to conventional used, assembled in this system. In this context, the main challenge in
Due to
e.g. cryogenic the fast
machining development
[1], dry machining in the domain of modelling and analysis is now not only to cope with single
lubrication, different approaches / strategieswith haveceramic tools
been used,
communication
[2]. cryogenic
Furthermore, and an
scientificongoing trend of digitization and products, a limited product range or existing product families,
e.g. machining [1],studies have shown
dry machining withthat controlled
ceramic tools
digitalization,
surface manufacturing
texture ofscientific
cutting tools enterprises are facing important but also to be able to analyze and to compare products to define
[2]. Furthermore, studieshas havealsoshown
potential to reduce
that controlled
challenges
cutting force, in today’s market environments: a continuing new product families. It can be observed that classical existing
surface texturetool of wear, etc.tools
cutting In other
has words, controlled
also potential to surface
reduce
tendency towards
texture force,
of cutting reduction
toolsetc.of
shows product development
potential times and product families are regrouped in function of clients or features.
cutting tool wear, In other words, for machinability
controlled surface
shortened
improvement product lifecycles. In addition, there
[3, 4]. tools shows potential for machinability is an increasing However, assembly oriented product families are hardly to find.
texture of cutting
demand of customization,
In study [5], being at the same time in a global On the product family level, products differ mainly in two
improvement [3,the
4].presence of laser texturing, i. e. microscale
competition
grooves with
on rake competitors
facepresence
of carbide all over the world. This trend, main characteristics:
Fig. 1. Diagram of the(i) the
liquid number
flowing intoofthecomponents and (ii)
tool – chip interface [5]. the
In study [5], the of tools
laser resulted
texturing, ini.decrease in the
e. microscale
which is
cutting force,inducing the
coefficient development
of friction, from macro to micro type of components (e.g. mechanical, electrical, electronical).
grooves on rake face of carbide toolssurface
resultedroughness
in decrease andintool
the Fig. 1. Diagram of the liquid flowing into the tool – chip interface [5].
markets, results in diminished lot sizes due to augmenting Classical methodologies considering mainly single products
cutting force, coefficient of friction, surface roughness and tool
product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the
2212-8271 © 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
identify
2212-8271 possible
© 2019 The optimization
Authors. Publishedpotentials in This
by Elsevier Ltd. the is existing
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Peer-review under responsibility of the scientific committee of the 52nd CIRP Conference on difficulties
article under regarding
the CC BY-NC-ND
Manufacturing Systems.
license an efficient definition and
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
production system, it is important to have a precise knowledge comparison of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the 52nd CIRP Conference on Manufacturing Systems.
2212-8271 © 2019 The Authors. Published by Elsevier Ltd.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/3.0/)
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under responsibility
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of the the scientific committee
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28th 52ndDesign
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10.1016/j.procir.2019.03.224
 Damir Grguraš et al. / Procedia CIRP 81 (2019) 904–907
2 Damir Grguraš and Franci Pušavec / Procedia CIRP 00 (2019) 000–000
that the texturing shape and orientation does affect the tool
performance. Li et al. [7] reported, that the tool with parallel
texturing to the main cutting edge provides the best
performance when turning titanium alloy Ti-6Al-4V. They also
noticed, that the implementation of the textures on the rake face
does not greatly affect the mechanical strength of the tools.
Comparable was concluded in [8]. In addition to the parallel
type (parallel textured tool), they reported that also square-dot
type of micro-textures (cross textured tool) improved
effectively the lubrication conditions in machining aluminium
alloy A6061-T6 [9]. In addition to turning process, influence of
textured carbide tools on milling performance was investigated
in [10]. It was found, that texturing on the rake face supress the
crater wear. Authors attributed this to the finding from [5], i. e.
texturing on the rake face is behaving as a micro-reservoir for a
cutting fluid. Additionally, they reported, that texturing can
behave also as a micro-trap for wear debris. A reduction in feed
and cutting forces when using textured cutting tools was also
reported in [11], where, unlike the above mentioned studies,
cutting oil was used as a flood. Following, elliptical [12] and
vertical [13] rake face texturing offered the best tool
performance in dry turning with solid particles (MoS2), where
the solid particles were filled into the textured rake face before
machining. In addition to dry machining with solid particles,
studies have been conducted also in completely dry machining,
where the texturing on cutting tools have ability to change the
contact area between the tool and the chip. This can reflect in
temperature reduction [14], lower built-up edge (BUE)
formation [15] and lower tool wear [16].
As presented above, most studies were carried out in turning
with carbide tools and flood conditions. Overall, carbide tools
with textured rake face can provide a better cutting
performance. However, tools’ performance is mainly
conditioned by the shape and orientation of the textures. In
addition, it is difficult to conclude the most effective surface
texture for machining performance improvement. Researchers
pointed that grooves parallel to the main cutting edge can offer
the best performance. In other studies however, a number of
other groove types can be traced, which also offer better
performance than non-textured tools. Therefore, performance
of carbide tools with different rake face texturing have been
tested and evaluated over following estimators: (i) cutting
force, (ii) chip shape and (iii) surface roughness.
2. Experimental procedure
2.1. Fabrication of rake face texturing
Surface texturing with different geometrical characteristics,
with the same texture depth of 0.2 mm on the rake face close to
the main cutting edge was made by laser machining. Fig. 2
shows comparison between inserts, i. e. without texturing and
with 8 different rake face texturing on carbide tools (main
cutting edge is marked yellow) used in turning experiments.
Presented rake face textures were determined based on
scientific literature review, wherein these eight textures can be
traced as the most representative.
905
Without texturing
Texturing 1
Texturing 2
4 mm 4 mm 4 mm
Texturing 3
Texturing 4
Texturing 5
4 mm 4 mm 4 mm
Texturing 6
Texturing 7
Texturing 8
4 mm 4 mm 4 mm
Fig. 2. Comparison of different rake face texturing on carbide tools used in
turning experiments (CAD models and real 3D optical images).
Textures on the cutting tools, presented in Fig. 2, can be
described, as follows: texturing 1 – circles with a diameter of
1.5 mm; texturing 2 – 0.5 mm wide arc-shaped grooves;
texturing 3 – rectangles of dimension 1.3 mm (next to the main
cutting edge) x 1 mm; texturing 4 – 0.3 mm wide elliptical
grooves; texturing 5 – 0.3 mm wide grooves perpendicular to
the main cutting edge; texturing 6 – 0.3 mm wide cross
grooves, i. e. perpendicular and parallel to the main cutting
edge; texturing 7 – 0.3 mm wide grooves parallel to the main
cutting edge and texturing 8 – 1 mm wide arc-shaped groove.
2.2. Machining experiments
To perform experiments, CNC lathe machine tool Mori
Seiki SL 153 was selected. Medium carbon structural steel
CK45 was used as a workpiece material in the form of rods
with a diameter of 50 mm and a length of 500 mm.
As a cutting material, uncoated tungsten carbide cutting
inserts were selected and following cutting parameters were
determined based on the cutting tool manufacturers’
suggestion: cutting speed, vc = 150 m/min, feed rate,
fn = 0.25 mm/rev, depth of cut, ap = 1 mm. Lead angle was 75°.
Turning length was 300 mm, equal for each experiment and all
experiments were executed in flood conditions using 7%
emulsion Blaser B-Cool 9665, which was delivered from the
outside on the rake face in the direction parallel to the main
cutting edge.
Influence of 9 different cutting inserts (without texturing +
8 different texturing) on machining performance was
determined using above presented conditions and estimated
over: (i) cutting force, (ii) chip shape and (iii) surface
roughness. Results obtained using insert without texturing were
considered as the reference.
Cutting force was measured using dynamometer Kistler
type 9129AASN. Chip shape was documented using
microscope Keyence VHX-6000. Surface roughness was
measured using surface roughness measuring device Mitutoyo
Surfest SF-301.
906 Damir Grguraš et al. / Procedia CIRP 81 (2019) 904–907
Damir Grguraš and Franci Pušavec / Procedia CIRP 00 (2019) 000–000 3

3. Results and discussion

Without texturing

Texturing 1

Texturing 2
3.1. Cutting force
1 mm 1 mm 1 mm
During machining experiments with different textured
cutting tools, main cutting force Fc was measured. Fig. 3 shows
influence of different rake race texturing on cutting force Fc.

Texturing 3

Texturing 4

Texturing 5
Results are showing, that parallel textured and cross textured
tools offers better performance in comparison to the reference
1 mm 1 mm 1 mm
(without texturing) and perpendicular textured tools. Texturing
8 provides the lowest Fc, which is for 7% lower than the
reference. Further, experiments performed using texturing 1, 4

Texturing 6

Texturing 7

Texturing 8
and 7 also resulted in lower cutting force compared to the
reference. The groove shape of texturing 1, 4, 7 and 8 allows
the emulsion to penetrate better into the cutting zone. 1 mm 1 mm 1 mm

Furthermore, such a form of grooves can act like a micro-

reservoir for constant emulsion replenishment, which results in Fig. 4. Influence of different rake face texturing on chip shape.
better lubrication and consequentially, lower cutting force.
4
Moreover, similar findings were obtained from other
researchers. 3.5
Surface roughness, Ra [µm] 3
3.2. Chip shape 2.5

2
Cutting tools with texturing on the rake face provide shorter
chips in comparison to the non-textured tool, as shown in Fig. 1.5

4. Tool texturing does change a shape of the rake face and also 1
a contact area between the rake face and the chip. This slightly 0.5
reduced and changed rake face surface can act as an additional
0
chip breaker, which then results in shorter chips. Although,
rake face texturing affects chip length in comparison to the
reference, there is no major difference between individual
textures.
Fig. 5. Influence of different rake face texturing on profile surface roughness
3.3. Surface roughness Ra.

After every experiment, surface roughness was measured. 4. Conclusions

Fig. 5 shows influence of different rake face texturing on
roughness Ra. Although, no major differences can be noticed
between experiments, texturing 4, 7 and 8, which also generate
lowest cutting force, provide slightly lower surface roughness.
510
490
Cutting force, Fc [N]
The machining performance of 8 different textured carbide
tools was compared with the non-textured carbide tool
(reference) under flood conditions. Influence of rake face
texturing on machining performance was evaluated over
cutting force, chip shape and surface roughness. Based on the
results, following conclusions can be drawn.
• Rake face texturing does affect machining performance of
carbide tools in comparison with non-textured carbide tool.
However, shape and orientation of the texturing does have

470 an influence on cutting force. Best performance provides

-7 %
parallel textured tools. This texturing form offers better
450 penetration of the emulsion and can serve as a micro-
reservoir for constant emulsion replenishment, i. e. better
430 cooling and lubrication.
• Although, the rake face texturing affects chip length in
410 comparison to the reference, there is no major difference
between individual textures.
• Carbide tool, which also generate lowest cutting force,
provides slightly lower surface roughness. However, there
are no major differences in surface roughness between
Fig. 3. Influence of different rake face texturing on cutting force Fc. individual textures and reference.
• Suggestion for future work – Investigation of the influence
of tool wear on the rake face texturing and on overall
 Damir Grguraš et al. / Procedia CIRP 81 (2019) 904–907
4 Damir Grguraš and Franci Pušavec / Procedia CIRP 00 (2019) 000–000
machining performance of textured uncoated tungsten
carbide tools. In addition, the influence of rake face
texturing on tool’s coating should be analyzed.
Acknowledgements
The authors gratefully acknowledge the support of the
Slovenian Research agency (ARRS) for founding the research
project L2-8184 and research program P2-0266.
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