Precision Engineering 49 (2017) 52–60

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Precision Engineering
journal homepage: www.elsevier.com/locate/precision

Original research paper

Performance of cutting tools with dimple textured surfaces: A

comparative study of different texture patterns
Tatsuya Sugihara ∗ , Toshiyuki Enomoto
Department of Mechanical Engineering, Graduate School of Engineering, Osaka University, 2-1, Yamada-oka, Suita, Osaka 565-0871, Japan

a r t i c l e i n f o a b s t r a c t

Article history: Recently, surface texturing has received much attention as a method of enhancing the tribological prop-
Received 10 August 2016 erties of a cutting tool surface. However, effective texture patterns and dimensions on a tool surface are
Received in revised form 2 December 2016 still difficult to obtain and suitable textures can be obtained only by trial and error. In order to overcome
Accepted 17 December 2016
this problem, we newly develop cutting tools with dimple-shaped textures having different dimensions
Available online 20 January 2017
and arrays, generated on the tool rake face. In addition, we evaluate their crater wear resistance and cut-
ting forces in steel material cutting. Furthermore, under various cutting conditions, the performances of
Keywords:
the cutting tools with dimple-shaped textures are compared with those of tools with groove-shaped tex-
Cutting
Cutting tool
tures in order to establish a guideline for designing appropriate surface textures on cutting tool surfaces. A
Tribology series of cutting experiments demonstrate that the dimple textures significantly improve the crater wear
Crater wear resistance and the tribological behavior on the tool rake face, and they exhibit a superior performance
Texture compared with those with groove textures, especially in a severely lubricated environment.
© 2017 Elsevier Inc. All rights reserved.

1. Introduction dimensions of the textures [5,7,14], there are no clear guidelines

Recently, surface texturing, as a method of improving the
tribological properties of mechanical components, has received sig-
nificant attention [1,2]. It has already been applied in some fields,
such as in the development of piston/cylinder systems [3]. In our
previous studies, we introduced this technology to cutting tool
surfaces to improve cutting tool performances. In fact, we devel-
oped several types of cutting tools with various textured rake and
flank faces. For example, we demonstrated that nanoscale and
microscale grooves on the tool rake face significantly improve the
anti-adhesive properties of the tool rake face in aluminum alloy
machining [4,5], and cutting tools with periodical stripe-grooved
rake and flank faces successfully decrease the crater and flank wear
in steel machining [6,7]. Furthermore, recently, several studies have
been conducted on cutting tools with textured surfaces [8–16].
These studies reported that surface textures on tool surfaces can
improve cutting performances in various metal cutting operations,
including decreasing the cutting forces [8–16], reducing the cut-
ting temperature [12,13,15], and improving the wear resistance
[11,12,15,16]. However, although the performances of the textured
rake and flank faces are known to be affected by the shapes and
∗ Corresponding author.
E-mail address: t-sugihara@mech.eng.osaka-u.ac.jp (T. Sugihara).
for designing effective textures on cutting tool surfaces, and these
parameters are currently determined only by trial and error. More-
over, although it was recognized that dimple-shaped textures are
effective for improving the tribological behavior in sliding surfaces
[3,17], most conventional studies focused on the performances of
the groove-shaped textures on the cutting tool surface. In addi-
tion, although only a few attempts were made to evaluate the
performances of cutting tools with microdimples or dots [9,18], the
advantages and disadvantages of the surface structures under vari-
ous cutting conditions were not discussed. Because dimples have a
“closed shape” structure, the dimple texture is expected to produce
different effects compared with the texture with microgrooves,
which have an “open shape” structure. Thus, different textures are
appropriate under different conditions.
In the present study, we newly developed cutting tools with
dimple-shaped textured surface having different dimensions and
arrays, generated on the tool rake face. A series of face milling
experiments were performed on medium carbon steel under wet
and dry cutting conditions, in order to evaluate the wear resistance
and cutting forces of the developed tools. Furthermore, the perfor-
mances of the developed tools with dimple-shaped textures were
compared with those of the tools with groove-shaped textures,
which were developed in our previous study [7], under various cut-
ting conditions, in order to discuss the advantages of each surface

http://dx.doi.org/10.1016/j.precisioneng.2017.01.009
0141-6359/© 2017 Elsevier Inc. All rights reserved.
 T. Sugihara, T. Enomoto / Precision Engineering 49 (2017) 52–60 53

Fig. 1. Developed cutting tool with a microdimple textured rake face (DT-01).

Table 1
Developed cutting tools with micro stripe textures.

Tool name Ddep (␮m) Ddia (␮m) Din (␮m) Ew (␮m) Array Ar (%)

Conventional – – – – 0
DT-01 5 50 75 30 Linear 35.0
DT-02 5 50 75 30 Zigzag 35.0
DT-03 5 30 75 30 Linear 12.6
DT-04 5 30 75 30 Zigzag 12.6
DT-05 5 70 75 30 Linear 68.3
DT-06 5 70 75 30 Zigzag 68.3
DT-07 5 50 95 30 Linear 22.0
Fig. 2. Parameters of dimple textures.
DT-08 5 50 95 30 Zigzag 22.0
DT-09 5 50 55 30 Linear 64.9
DT-10 5 50 55 30 Zigzag 64.9
texture and to establish a guideline for selecting the appropriate
texture for a cutting tool surface.

2. Experimental details

2.1. Development of cutting tool with dimple textured surface

To generate microdimples on the tool surface, laser surface

texturing (LST) using femtosecond laser [19,20] was employed. A
microdimple array was generated on the rake face of a WC-Co
cemented carbide cutting tool (ISO P10-type, Non-coated tool) by a
Yb:KGW-based laser system (L.P.S Works Co. Ltd., PiCooLs4; wave-
length = 515 nm, pulse width = 190 fs, cyclic frequency = 400 kHz).
Fig. 1 shows a scanning electron microscope (SEM) image, a 3-
dimensional image and a sectional profile of the rake face a
developed tool. The microdimples, which have a rectangular cross-
section, were fabricated on the rake face of the WC-Co cemented Fig. 3. Experimental setup of face milling tests.
carbide cutting tool with a 100-␮m-wide chamfer. In order to
investigate the influence of the texture dimensions and arrays,
10 different types of cutting tools were prepared. Fig. 2 shows where Aconvex and Aconvex are the area of convex and concave of
a schematic illustration of the parameters of the dimple texture, each textured rake face.
and Table 1 summarizes the characteristics of the developed cut-
ting tools, which corresponded to from DT-01 to DT-10. In this 2.2. Experimental setup
study, depth of the dimples (Ddep ) and edge width of non-textured
area (Ew ) were set at 5 ␮m and 30 ␮m, respectively. Two different The cutting experiments were conducted on medium carbon
array patterns; namely, a linear array (Fig. 2(a)) and a zigzag array steel (carbon content: 0.51–0.55%) using a vertical machining cen-
(Fig. 2(b)), were prepared. The area ratio Ar of each textured surface ter (Yamazaki Mazak Corp., AJV-18). The experimental setup is
was calculated by the following equation illustrated in Fig. 3. Fig. 4 shows the geometry of the cutting tool
with a single insert. The center of the cutter was set on the cen-
Ar = Aconcave /(Aconcave + Aconvex ) (1) terline of the workpiece. Table 2 lists the cutting conditions. An
54 T. Sugihara, T. Enomoto / Precision Engineering 49 (2017) 52–60

emulsion type cutting fluid diluted by 10 times was supplied from

two nozzles which were set on the tool rake face side and tool flank
face side at a flow rate of 12.6 L/min in the wet cutting experiments.
In order to evaluate the performances of each cutting tool, the
rake face of the cutting tool was measured using a laser microscope
(Keyence. Corp., VK-X250) and observed by an SEM (Hitachi Hi-
Technologies Corp., TM3000). In addition, three components of the
cutting forces were evaluated using a dynamometer (Kistler Co.,
Ltd., 9257B) which was set under the workpiece material.

3. Performance of a cutting tool with a dimple texture

Fig. 4. Geometry of the cutting tool. 3.1. Wear resistance under the wet cutting condition

Fig. 5 summarizes the crater wear depth of the conventional

cutting tool with a smooth rake face and those for each developed

Fig. 5. Maximum depth of crater wear of conventional and developed tools under the wet cutting condition (Cutting speed: 200 m/min, Feed rate: 0.20 mm/tooth).

Fig. 6. Profiles of the rake face of cutting tools after wet cutting for 300 m (left: 3-dimensional profile; right: cross-section profile, Cutting speed: 200 m/min, Feed rate:
0.20 mm/tooth).
 T. Sugihara, T. Enomoto / Precision Engineering 49 (2017) 52–60 55

Fig. 7. Relationship between the amount of crater wear and the area ratio of the textured rake face under the wet cutting condition (Cutting speed: 200 m/min, Feed rate:
0.20 mm/tooth).

Fig. 8. Maximum depth of crater wear of conventional and developed tools under the dry cutting condition (Cutting speed: 200 m/min, Feed rate: 0.20 mm/tooth).

Fig. 9. Relationship between the amount of crater wear and the area ratio of the textured rake face under the dry cutting condition (Cutting speed: 200 m/min, Feed rate:
0.20 mm/tooth).

tool after cutting for 300 m under the wet cutting condition. In this
figure, the depths of the crater wear are the average values cal-
culated from five different profiles obtained by the measurement
results of the laser microscope. As shown in this figure, severe crater
wear, approximately 9 ␮m deep, occurred on the rake face of the
conventional tool without a surface texture. On the other hand,
Fig. 5 clearly indicates that some of the developed tools signifi-
cantly suppressed the crater wear compared with the conventional
cutting tool. Fig. 6 shows the 3-dimensional images and sectional
profiles of the conventional tool and DT-05, which shows one of the
most excellent wear resistances among the developed tools. These
results confirm that DT-05 reduced the maximum depth of the
crater wear from 9 ␮m, obtained in the conventional tool (Fig. 6(a)),
56 T. Sugihara, T. Enomoto / Precision Engineering 49 (2017) 52–60

Fig. 10. SEM images of the rake faces of DT-05 and DT-09 after dry cutting (Cutting speed: 200 m/min, Feed rate: 0.20 mm/tooth).

Fig. 11. Fn and Ff of conventional tool and DT-05 under wet and dry cutting conditions (Cutting speed: 200 m/min, Feed rate: 0.20 mm/tooth).

to 3 ␮m (Fig. 6(b)), and the microdimples at the tool-chip contact
area still remained even after cutting for 300 m.
Moreover, Fig. 7 indicates the relationship between the area
ratio of the textured rake face and the amount of the crater wear
under the wet cutting condition. In this figure, the area ratio is con-
sidered to be zero for the conventional tool. This figure suggests
that the wear resistances of the developed cutting tools strongly
depend on the area ratio of the textured surfaces. When the area
ratio is less than approximately 20%, the dimple textures are inef-
fective for improving the crater wear resistance. On the other hand,
when the area ratio is more than 20%, the wear resistance of the
dimple-textured rake face is improved in proportion to the increase
of the area ratio of the textured rake face. Furthermore, comparing
Fig. 7(a) with Fig. 7(b), it is confirmed that the array patterns have
little influence on the amount of the crater wear of the developed
tools under the cutting condition of this experiment.
3.2. Wear resistance under the dry cutting condition
Fig. 8 summarizes the depth of the crater wear of the conven-
tional tool and that of each developed tool after cutting for 300 m
under the dry cutting condition. As shown in this figure, the crater
wear depths of the conventional and the developed tools were
increased compared with that in the wet cutting condition (Fig. 5).
This is because the cutting temperature was increased and the
lubricity at the tool-chip interface was decreased without the use of
the cutting fluid. On the other hand, Fig. 8 also indicates that some
of the dimple textures are still effective for improving the crater
wear resistance even under the dry cutting condition, whereas the
difference of the wear amount between the conventional and the
developed tools was diminished.
In addition, Fig. 9 indicates the relationship between the area
ratios of each textured rake face and the amount of the crater wear
 T. Sugihara, T. Enomoto / Precision Engineering 49 (2017) 52–60 57

Table 2
Cutting conditions.

Workpiece Medium carbon steel (C: 0.51–0.55%)

W 60 (mm) – L 66.4 (mm)
Tool Cemented carbide P10, Non-coated tool
SEKN42MT, (Sumitomo Electric Hardmetal
Corp.)
Tool geometry Axial rake angle, ␪A 20◦
Radial rake angle, ␪R −3◦
True rake angle, ␣ 12.4◦
Corner angle, ␥ 45◦
Cutter diameter, D 80 (mm)

Cutting speed 200 (m/min); 800 (rpm)

Depth of cut 2 (mm)
Feed rate 0.20 (mm/tooth)
Cutting length 300 (m)
Cutting fluid -Wet: Emulsion type (JIS A1)
Finecut CFS-100, (NEOS CO., LTD.)
-Dry
-Paste: Chlorine free type
C-100, (NIHON KOHSAKUYU Co., Ltd.)
Supply rate 12.6 (L/min)
under the dry cutting condition. In contrast to the result of the wet
cutting condition (Fig. 7), there are some difference in the wear
amount between DT-05, DT-06, DT-09, and DT-10, although they
have almost the same area ratios. Fig. 10 shows SEM images of the
rake face of DT-05 and DT-09 after cutting for 300 m, suggesting that
the microdimples of DT-09, which have smaller diameters, were
almost buried by the adhesions of the workpiece material, whereas
that of DT-05 were still existed. This result suggests that, when
the area ratio is the same, the dimples with larger diameter, such
as those on DT-05 and DT-06, are effective under the dry cutting
conditions. This is because sever chip adhesion inevitably occurs
without the use of the cutting fluid regardless to the size of dimples,
and smaller dimples, such as those on DT-09 or DT-10, are easily
buried by the small amount of the chip adhesions.
3.3. Mechanism for suppressing crater wear
Several possible factors may decrease the crater wear on the
dimple-textured rake face. In particular, the dimples might serve
as (i) a micro-reservoir for a cutting fluid, and (ii) a micro-trap for
wear debris [7]. During cutting processes, it is difficult to supply cut-
ting fluids to the tool-chip interface due to a high contact pressure,
even using an adequate amount of cutting fluids [21]. In contrast,
the microdimple texture is expected to retain the cutting fluid on
the tool rake face and bring about the cooling and lubricant effects
of the fluid at tool-workpiece interface, thus reducing the interface
temperature and the friction between the tool and chip. In addi-
tion, hard wear debris that falls out of cutting tools and workpieces
plows the tool surface, promoting abrasive wear and increasing
friction [22,23]. Furthermore, our previous study showed that this
mechanical abrasion by the plowing caused by the wear debris
is one of the factors for accelerating the crater wear of a WC-Co
cemented carbide cutting tool in steel machining process [7]. In
such a case, the microdimple texture is expected to trap the wear
debris and prevent it from plowing the tool surface. In this chapter,
in order to confirm the mechanisms for suppressing the crater wear
of the textured surfaces, as described above, the cutting forces are
measured under both wet and dry cutting conditions.
The cutting force components perpendicular to the tool rake face
(Fn ) and parallel to the tool rake face (Ff ) were calculated from the
three components of cutting forces obtained by the dynamometer.
Fn and Ff were derived from the average cutting forces of 10 con-
tinuous rotations, when the component of Y-direction (see Fig. 3)
reaches the peak value in each rotation of the cutter. Fig. 11 shows
Fn and Ff of the conventional tool with a smooth rake face and that
Fig. 12. Friction coefficient at tool-chip interface under wet and dry cutting condi-
tions (Cutting speed: 200 m/min, Feed rate: 0.20 mm/tooth).
of DT-05 under the wet and dry cutting conditions. As shown in
this figure, Ff of DT-05 is smaller than that of the conventional tool
under both cutting conditions, whereas there is little difference in
Fn between the two conditions, indicating that the textured rake
face particularly affected the frictional properties at the tool-chip
interface during the machining process. Furthermore, Fig. 12 shows
that the friction coefficient at the tool-chip interface of the tools
derived from the ratio between Fn and Ff . The friction coefficient of
DT-05 is lower than that of the conventional tool even under the
dry cutting condition, suggesting that the dimple texture serves as
a micro-trap for wear debris at tool-chip interface, because such
an effect can be obtained without any lubricant and coolant. In
addition, the better wear resistance of DT-05 in the dry cutting
condition, which is shown in Fig. 8, is thought to be caused by the
effect of the micro-trap for wear debris. Moreover, by comparing
the wet and dry cutting, the friction coefficient of DT-05 in the wet
cutting is much smaller than that in the dry cutting, whereas there
is little difference in the conventional tool. This means that, dur-
ing wet cutting process, the microdimples act as a micro-reservoir
for the cutting fluid. Therefore, the developed tools with a larger
area ratio, which are capable of retaining more cutting fluid at the
tool-chip interface, show better wear resistance especially under
the wet cutting condition.
4. Dimple-shaped vs. groove-shaped texture
4.1. Performance of cutting tools with microgrooves
Fig. 13 shows a cutting tool with microgrooved rake face, which
is named MS-01. In this tool, periodical rectangular grooves 5 ␮m
deep and 20 ␮m wide/apart are generated on the rake face of
the WC-Co cemented carbide cutting tool with a 100-␮m wide
chamfer. In our previous study [7], the wear resistances of the
microgrooved rake faces with different texture dimensions and
directions were investigated under various cutting conditions, and
the study revealed that MS-01 was one of the developed tools show-
ing excellent crater wear resistance. In this section, first, the wear
resistance of MS-01 under the same cutting conditions listed in
Table 1 was evaluated.
Fig. 14 shows the 3-dimensional images and sectional profiles
of MS-01 after wet cutting for 300 m. This figure shows that MS-
01 significantly suppressed the crater wear from 9 ␮m, obtained in
the conventional tool (Fig. 6(a)), to 3 ␮m (Fig. 14), indicating that
the microgrooves have approximately the same potential as the
microdimples in the steel cutting operation. In addition, it is also
confirmed that the microgrooves at the tool-chip contact area still
remained even after cutting for 300 m.
58 T. Sugihara, T. Enomoto / Precision Engineering 49 (2017) 52–60

Fig. 13. Developed cutting tool with micro stripe textured rake face (MS-01) [7].

Fig. 14. Profiles of the rake face of MS-01 after wet cutting for 300 m (left: 3-dimensional profile; right: cross-section profile, Cutting speed: 200 m/min, Feed rate:
0.20 mm/tooth).

Fig. 15. Schematic illustration of the paste cutting process.

4.2. Comparative evaluation of the different surface textures

Structures of surface textures can be divided into two groups:

“open shape” structures and “closed shape” structures. The former
(including microgrooves) has continuous concave areas, which are
connected from a contact area to a noncontact area at the tool-chip
interface on the tool rake face. On the other hand, the closed shape
structures (including microdimples) consist of independent con-
cave areas, which are separated from each other. In order to discuss
the advantages of each surface texture and to establish a guideline
for selecting the appropriate surface texture for a cutting tool sur-
face, the cutting performances of the tool with the dimple texture
and that with the grooved texture were investigated under three
different lubricating conditions; namely, wet, dry and paste cutting
conditions. Under the paste cutting condition, a paste-type lubri- Fig. 16. Friction coefficient at tool-chip interface under different cutting conditions
(Cutting speed: 200 m/min, Feed rate: 0.20 mm/tooth).
cant was applied on the side face of the workpiece material where
the cutter was engaging. In that case, the lubricant is supplied to
the tool-chip interface only when the tool is engaging with the such as inflow and out flow properties, were investigated by com-
workpiece material, in every rotation period, as shown in Fig. 15. paring the friction coefficient under the three cutting conditions.
Therefore, the lubricating condition at the tool-workpiece interface Fig. 16 indicates the friction coefficient of the conventional tool,
becomes more severe in the order of dry > paste > wet cutting con- DT-05, and MS-01 for each lubricating condition. As shown in this
dition, and the lubricant behaviors at the tool-workpiece interface, figure, the friction coefficients of DT-05 and MS-01 were much
 T. Sugihara, T. Enomoto / Precision Engineering 49 (2017) 52–60
Fig. 17. SEM images of the rake faces of DT-05 and MS-01 (Cutting speed: 200 m/min, Feed rate: 0.20 mm/tooth).
smaller than the friction coefficient of the conventional tool under
the wet cutting condition. MS-01 showed slightly better tribolog-
ical properties compared to DT-05, even though area ratio Ar of
MS-01 (50%) is smaller than that of DT-05 (68.3%). This might be
because, in the case of the grooved rake face, the cutting fluid pene-
trates into the tool-chip interface from the end of the grooves while
the tool rake face is in contact with the chips, because the grooved
rake face has an “open shape” structure. In addition, microgrooves
can supply the retained cutting fluid evenly to the tool-chip inter-
face due to their continuous shape. These results suggest that open
shape structures, such as microgrooves, have a potential to show
superior lubricity compared to closed shape structures with the
use of an adequate amount of cutting fluids, due to their excellent
in-flow property of the cutting fluids.
On the other hand, under the paste cutting condition, DT-05,
which has the dimple texture, exhibits the lowest friction coeffi-
cient. In the case of paste cutting, the effect of retaining lubricants
in the surface textures becomes more important, because the lubri-
cant is not supplied to the cutting tool during the contact period of
the tool surface with the workpiece material. Therefore, the rake
face with the microdimples, which are “closed shape” structures,
shows better tribological behavior. On the contrary, microgrooves
have a risk of a flowing-out of lubricant from the structure. Fur-
thermore, Fig. 17 shows enlarged SEM images of the worn areas
on the rake faces of DT-05 and MS-01, indicating that the work-
piece material was locally adhered to the edge of the microgrooves
(Fig. 17(b)). Ma et al. reported that a surface texture on a tool
rake face can act as a microcutter of chips during cutting process
[24], which leads to the increase of friction and local chip adhe-
sions at the edge of surface textures. The SEM image indicates that
the microgrooves particularly provide this adverse effect without
the use of the cutting fluid compared to the microdimples, and
the advantages of the surface texture might be diminished by the
local chip adhesion. In conclusion, these results indicate that closed
shape structures, including microdimples, exhibit superior perfor-
mance, as compared to open shape structures, especially in a severe
lubricating environment.
5. Conclusions
In this study, cutting tools with microdimple textured surfaces
on their rake face were developed in order to improve the wear
resistance in cutting of steel materials. In addition, a compara-
tive evaluation between the microdimples and microgrooves was
conducted, with the following findings:
(1) Microdimples on the rake face of a cutting tool effectively sup-
press the crater wear in cutting medium carbon steels, and the
effect can be obtained even under dry cutting conditions. The
wear resistance of the textured rake face has a strong correla-
59
tion with the ratio between the concave and convex area of the
textured rake face.
(2) From the analysis of the cutting forces, it was clarified that the
textured surface improves the crater wear resistance by serving
as (i) a micro-reservoir for a cutting fluid, and (ii) a micro-trap
for wear debris.
(3) The cutting performances of a tool with dimple texture and
that with grooved texture under various lubricating condi-
tions were investigated. The experimental results show that
“closed shape” structures, such as microdimples, can exhibit
superior performance, especially under a severe lubricating
environment, although “open shape” structures, including
microgrooves, also perform satisfactorily when using a great
quantity of flooded cutting fluid.
Acknowledgments
We thank everyone at L.P.S. Works Co., Ltd., and Neos Co., Ltd.,
for their invaluable assistance and advice.
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