3D-FEM simulation optimization and tool wear mechanism study of groove-textured tools in precision milling of compacted graphite iron

Abstract

Compacted Graphite Iron (CGI) is a difficult-to-machine material with intense friction at the tool-chip interface. This leads to severe adhesive wear on the cutting tool, negatively impacting machining quality and efficiency and limiting the application of CGI. Micro-textured tools with appropriate texture parameters effectively reduce friction and adhesion between the tool and chip during dry cutting. In this study, groove-textured tools with varying texture parameters were prepared and used for milling CGI. By combining finite element simulation and experimental methods, the effects of different texture parameters on cutting force and cutting temperature were investigated, and the optimal texture parameters were determined. Additionally, single-factor experiments and tool life tests were conducted on textured and non-textured tools to reveal the wear mechanisms of textured tools during CGI milling. The experimental results indicate that the cutting performance of the micro-textured tool is optimal when the groove width is 80 µm, the groove-to-edge angle is 30°, the groove-to-edge distance is 50 µm, and the groove spacing is 150 µm. The micro-texture significantly reduces the adhesive wear on the tool’s rake face but does not alter the wear mechanism. The tool life results demonstrate that micro-textured tools extend tool life without significantly changing the wear stages.