Cutting Performance of YG8 Cemented Carbide Tools with Microcapsule-Filled Surface Microtextures

Area of Science:

• Materials Science and Engineering
• Tribology
• Manufacturing Technology

Background:

• Dry cutting of YG8 cemented carbide tools faces challenges with performance and tool wear.
• Developing advanced self-lubricating systems is crucial for improving machining efficiency and tool life.

Purpose of the Study:

• To enhance the dry cutting performance of YG8 cemented carbide tools.
• To investigate the effectiveness of a microcapsule-microtexture composite self-lubricating tool system.

Main Methods:

• Incorporation of CaF2/[BMIM]PF6@PPSU solid-liquid dual-core microcapsules into microtextures on the rake face.
• Systematic investigation of microcapsule content and microtexture edge spacing effects on cutting performance through cutting experiments.
• Analysis of tool wear mechanisms using micromorphological and energy-dispersive spectroscopy (EDS).

Main Results:

• Optimal cutting performance achieved at 20 wt.% microcapsule content and 100 μm edge spacing.
• Significant reductions in main cutting force (approx. 40%), cutting temperature (43.9%), and surface roughness (24.5%) compared to unlubricated tools.
• Extended cutting distance up to 9497 m under optimal conditions.

Conclusions:

• The microcapsule-microtexture composite system effectively improves dry cutting performance of cemented carbide tools.
• The released solid-liquid biphasic lubricating film suppresses adhesive and abrasive wear, mitigating delamination and adhesive wear.
• Optimized microcapsule content and microtexture design are key to achieving superior tribological performance in machining.