On the comparative cutting performance of nature-inspired structured cutting tool in dry cutting of AISI/SAE 4140

In this study, femtosecond laser was used to create micro-structures on the flank face of a cutting tool. For the first time, a nature-inspired design (shape) of structure was created and explored. The inspiration for the nature-inspired design was the ball python (snake). This is because these creatures have high resistance to damage, originating from skin surface design feature. This was the main reason in replicating its scale design on cutting tool surface. Orthogonal cutting test was performed on AISI/SAE 4140 at the cutting speeds of 283 and 628 m/min and a feed of 0.1 mm/rev to study the effects of structure shapes. Results showed that nature-inspired design structures significantly reduced forces, temperature, compression ratio, contact length and power consumption. Characterisation of sticking and sliding contact was also made.