Journal of Materials Processing Tech.

293 (2021) 117096

Contents lists available at ScienceDirect

Journal of Materials Processing Tech.

journal homepage: www.elsevier.com/locate/jmatprotec

Review

State of the art of tool texturing in machining

Alisson R. Machado a, b, *, Leonardo R.R. da Silva a, b, Felipe C.R. de Souza b, Rahul Davis c,
Leandro C. Pereira b, Wisley F. Sales a, 1, Wagner de Rossi d, Emmanuel O. Ezugwu e, 1
a
Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná – PUC-PR, CEP 80215-901, Curitiba, PR, Brazil
b
Federal University of Uberlandia, School of Mechanical Engineering, Av. João Naves de Ávila, 2121, Bloco 1M, 38400-902, Uberlândia, MG, Brazil
c
Department of Mechanical Engineering, National Institute of Technology Patna, Patna, 800005, India
d
Centro de Lasers e Aplicações, Instituto de Pesquisas Energéticas e Nucleares - IPEN, São Paulo 05508-000, Brazil
e
AFIT – Air Force Institute of Technology, Kaduna, Nigeria

A R T I C L E I N F O A B S T R A C T

Associate Editor: Jian Cao In most of the machining processes, the application of surface texturing is one of the most remarkable and
promising research fronts in relation to the use of tribological concepts for improving machinability. This paper
Keywords: aims to review the most recent articles on this theme (from 2016 to date) to assist the researchers in the state of
Surface texturing the art of this technology, guide the forthcoming related investigations, and thus, fill the identified research gaps.
Cutting tools
The texture effect in machining was comprehensively reviewed considering chip formation, cutting forces,
Chip formation
cutting temperature, lubrication, surface integrity, and tool life. The present review highlights and summarizes
Machinability
the major findings with emphasis on the influencing parameters, such as workpiece and tool material, cutting
process, lubri-cooling condition, texture geometry, and texture manufacturing technique. The overwhelming
majority of the studies presented tool surface textures manufactured by laser ablation on the rake face of un­
coated WC-Co tools. In this relation, turning was identified as mostly used machining process and dry condition
as the chiefly implemented lubri-cooling environment. Moreover, most of the textures were noticed with linear
grooves and dimple geometries, whereas the work materials mostly investigated were the hardened/high alloy
steels and titanium alloys.

1. Introduction titanium alloys (Gupta and Laubscher, 2017). This further increases the
already-high complexity of the interactions at the cutting interfaces. In
The technological development of humanity is inevitably linked to addition to the utilization of more sustainable cooling techniques
its ability to advance the tooling system. It is interesting to know that the (Debnath et al., 2014), the most advanced research fronts are getting
historical periods were divided based on materials used in tool pro­ focused on the development of tools and coatings (with an
duction, such as stone, bronze, and iron ages. Even in the contemporary ever-increasing combination of hardness and toughness) (Favero Filho
era, this remains valid where the emergence of more technologically et al., 2019) for improving efficiency and environmental impact of the
intricate devices occurs concurrently with the development and machining processes.
advancement of more complex materials. Cutting fluids are another front of research that has called attention
Interactions at chip/tool/workpiece interfaces adversely affect the in recent years because, on the one hand, they may be indispensable
machining tribosystem since in relatively closer surfaces (such as the from the technical point of view; on the other hand, they usually cause
primary and secondary shear planes), the mechanical and thermal adverse environmental impact. Therefore, the interaction of textured
stresses exhibit huge differences, thus, give rise to entirely different tools and the use of cutting fluids is another interesting matter to
tribological interactions, tool wear mechanisms, and machining per­ consider.
formances (Astakhov, 2006). The tribosystem is further aggravated by The assertive given by Moore (1969) that the surface texture is the
the growing demand for materials with higher mechanical, thermal, and most crucial variable regarding the magnitude of frictional interactions
tribological properties, such as nickel (Thellaputta et al., 2017) and between coupled surfaces remains as relevant as ever. Despite its

* Corresponding author at: Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná – PUC-PR, CEP 80215-901, Curitiba, PR, Brazil.
E-mail address: [email protected] (A.R. Machado).
1
In memoriam.

https://doi.org/10.1016/j.jmatprotec.2021.117096
Received 7 June 2020; Received in revised form 31 January 2021; Accepted 7 February 2021
Available online 10 February 2021
0924-0136/© 2021 Elsevier B.V. All rights reserved.
A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

implementation and evaluation in ancient times (Gachot et al., 2017) by with respect to the main output parameters of the machining processes.
historical figures such as Leonardo Da Vinci (Hutchings, 2016), the Therefore, the present review intends to provide research and knowl­
modern approach to implement surface textures in engineering was edge gaps to the budding researchers for executing more advanced
driven by pioneer studies which involved the evaluation of the so-called research in surface texturing of cutting tools involved in various
micro-asperities in mechanical seals and bearings, such as the works machining processes.
conducted by Hamilton et al. (1966) on the theory of lubrication under
micro-asperities, Anno et al. (1969) studies about the effect of 2. Chip formation
micro-asperities in load-support and fluid leakage and Etsion and Bur­
stein (1996) model for mechanical seal under the effect of According to Shaw and Cookson (2005), the mechanism involved in
micro-asperities. the chip formation process may cause harm to the machine operator and
With the advent and popularization of surface engineering tech­ damage the equipment or product. In addition, machinability variables
niques, the investigation of surface texture’s significance on cutting tool such as cutting forces, temperature, lubrication, and tool life, including
performance amid machining processes has gained immense attention material handling and disposal, may also be adversely affected. All the
(Sharma and Pandey, 2016b). Surface texture fabrication techniques in aforementioned reasons corroborate the importance of chip formation
cutting tools do not differ much from those commonly applied ones used understanding to achieve a successful cutting operation. Even though
for texturing other components such as pistons/cylinders (Da Silva and the chip movement is restricted to a great extent by its interaction with
Costa, 2017a,b), mechanical seals (Wang et al., 2019), bearings the rake surface, all other machining parameters have some degree of
(Vlădescu et al., 2019), and prostheses (Baino et al., 2019) with the most effect on its formation. Based on these arguments, the implementation of
common methods such as laser, electrical discharge, and electron beam surface texturing mainly on the tool rake surface holds a promising
texturing (Arslan et al., 2016). The relatively lower understanding of the dominance for controlling the chip formation process. Moreover, surface
effects of surface texturing of cutting tools on the various factors texturing on the tool rake surface directly affects the tribological
affecting machinability still hinders applying this technique on a larger behavior in the secondary shear zone because of modification of the
scale (Ranjan and Hiremath, 2019). contact area in the seizure and slipping zones.
Most published research addressing various insights of surface In general, the literature indicates that textures perpendicular to the
texturing of cutting tools are focused on the surface manufacturing chip flow result in a decrease in the chip curling radius, favoring its
techniques (Ranjan and Hiremath, 2019) and tribological effects of the breakage (Kang et al., 2018b). Su et al. (2018) reported that texture
texture (Chen et al., 2019b). Moreover, some related researches are patterns perpendicular to the chip flow are more efficient to trap debris
covered by a relatively smaller number of articles consisting of the generated during the chip formation. According to Sivaiah and Bod­
actual state of the art (Gajrani and Ravi Sankar, 2016), and most of them icherla (2020), the debris trapping is even more efficient with the
applied in areas other than machining. The machining tribosystem has perpendicular groove pattern, resulting in lower friction at the chip flow
contact pressures of the orders of magnitude higher than those found in interface. The better performance of the perpendicular textures in
most mechanical systems such as sliding and rolling bearings (Rose­ relation to the chip flow was further assessed from a tribological point of
nkranz et al., 2019) and even higher than those found in forming pro­ view by Dhage et al. (2019) using a lathe as an open tribometer and
cesses (Shimizu et al., 2019). This happens because in machining the evaluating the correlation between the tool-chip contact area and the
pressures at the chip-tool-workpiece interfaces must be high enough to cutting force with the roughness parameters of the textured rake surface
allow shearing of the work material to form the chip properly. of the tool. Despite that, the texture parallel to the chip flow led to a
Such high pressures make it impossible to apply hydrodynamic lower derivative cutting at the texture borders, as reported by Liu et al.
models such as those described by Gropper et al. (2016) or (2017).
elasto-hydrodinamic as described by Marian et al. (2019). Despite the As described by Duan et al. (2019), one of the biggest challenges
recent advances in surface texturing technology, most of the evaluations regarding chip formation in textured cutting tools is to reduce the for­
are, as shown by Grützmacher et al. (2019), focused on contact pressures mation of derivative cutting zones at the edges of the textures. This
much lower than those found in machining. Thus, models for design and phenomenon increases the shear stresses by generating additional shear
optimization, such as those presented by Gropper et al. (2018), could not zones resulting in increased machining forces and wear, especially at the
be promptly used to model the cutting interface tribosystems. textured region.
The abovementioned facts provide solid grounds for the present Mishra et al. (2018a) developed a model for the chip serration and
paper to review all the related latest publications (2016 to date). This contact length for plain and textured tools based on a linear regression
timespan is further supported by the fact that some of the major reviews model, which can be used for 2D machining simulations. The simulation
in the field focused on papers from before 2016. To exemplify, Sharma results are shown in Fig. 1 and the chips are seen embedded in the
and Pandey (2016b) review about surface texturing focused on the textures at greater feed rates. In the case of vc =200 m / min and vc
turning process, which will be evidenced in this paper’s conclusion, =250 m / min, the chips completely incorporate the textures in the
indicating that the study of the effects of textures in other machining contact zone. Besides this, broken textures are visible in the simulation
processes is neglected. Arslan et al. (2016) focused on texture results. Therefore, it can be proposed that textured tools lose their
manufacturing technologies and the resulting tribological interactions, effectiveness with increased feed and speed due to high embedding and
not providing enough information about the effects of textures on texture reduction. The higher von Mises stresses on the flank and on the
machinability. Gajrani and Ravi Sankar (2016) also focused on texturing rake faces are visible from the simulation results. The contact stresses
manufacturing methods. The discussion in this paper is focused on the where the chips are embedded in the textures are comparatively higher
effect of the cutting tool surface texturing on the machinability response than the unfilled textures, suggesting dullness or wear of the textures
parameters. Besides, the influence of various texturing techniques, ge­ due to higher stresses. The hot chips embedded in the textures will act as
ometries, and texture positions for different cutting processes and pa­ a heat source and cause thermal damage to the tools and, ultimately,
rameters and machined materials, has been included as part of the break patterns due to high stresses.
present review. Patel et al. (2019) studied the dry turning process of AISI 4340 steel
The cutting processes, as usual, have been addressed in terms of the using uncoated micro-textured cemented carbide tools. The textures
influence on chip formation, cutting forces and power, cutting temper­ used were microgrooves perpendicular to the cutting edge, produced by
atures, lubrication, surface integrity, and tool life. Further, to summarize micro-electrical discharge machining (μ-EDM) along the tool’s rake face.
the state of the art, this manuscript presents a graphical review related to The textures varied with respect to the width (50 and 100 μm), depth
the investigation of the performance of cutting tools surface texturing (10, 20 and 30 μm), and spacing (50, 75, 100, 150 and 200 μm). The

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 1. Simulation results for contact length for textured cutting tools for several cutting conditions. Adapted from Mishra et al. (2018a).

authors found that increased groove width and spacing reduced the chip flow reduced the stresses in the cutting tool. Similar conclusions
chip-tool contact and decreased the chip flow and adherence of the work regarding the groove direction influence in the chip formation were
material into the microgrooves. Changes in the micro-groove depth found by Arulkirubakaran et al. (2019). Durairaj et al. (2018) also
proved to be less effective in the chip control. concluded that surface texturing in the cutting tools resulted in around
In the dry turning of the AISI 52100 steel, Kumar and Patel (2018) 15 % less adhesion than un-textured tools.
studied the effect of groove textures on the rake surface of Al2O3/TiCN Su et al. (2017) investigated the performance of textures on poly­
composite ceramic cutting tools with EDMed textured tools. The width crystalline diamond (PCD) tools in dry turning of Ti6Al4V titanium
of the textures varied between 150 μm and 200 μm, with a distance alloy. Regular microgrooves (parallel to the main cutting edge) were
between the patterns ranging from 300 μm to 400 μm. The authors fabricated on the rake face of tools by a fiber laser with groove depths
found that textures perpendicular and parallel to the chip flow direction ranging from 51.5 μm to 54.4 μm, groove width from 56.5 μm to
resulted in a reduction and increase of friction, respectively, when 60.4 μm, spacing from 83.9 μm to 86.4 μm, and groove distance (from
compared to non-textured cutting tools. Despite the sliding condition the main cutting edge) from 249.8 μm to 330.9 μm. The authors found
being the significant curling effect for the chips in all situations, the that the tool-chip interface’s frictional behavior was significantly
textures perpendicular to the chip flow resulted in greater chip-curling. improved by the micro-grooved tools compared to that of the
The authors also found that textures that obstructed the chip flow non-textured tools, even without the use of lubricants. Other authors
reduced the material adhesion on the tool face compared to also found improvements in the tool-chip interface’s frictional behavior,
non-textured tools, and the texture direction inclined or normal to the such as Feng et al. (2017) who reported reductions of up to 30 % in

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

relation to non-textured tools. The textures were manufactured using a wire-EDM (wire electrical
Chen et al. (2017) made numerical investigations of the effects of discharge machining) process with microgrooves perpendicular to the
microgroove laser textured uncoated cemented carbide tools. The mi­ chip-flow direction at two levels of spacing (72 ± 10 and 110 ± 10 μm).
crogrooves were designed on the tool’s rake face, perpendicular to the The fluid flow rate was kept constant at 7.5 ml/h with application at two
chip flow, with the edge distance ranging from 20 to 200 μm, groove pressure levels (2 and 4 bar). For a better comparison, the machining
width ranging from 30 to 200 μm, and width-to-depth ratio from 1 to 16. conditions were also evaluated under the dry condition using
The authors found that the microgrooves could be effective in reducing non-textured tools. The authors found that the surface texturing resulted
the cutting and thrust forces in general. The authors also found an in provisional chip collection in the rake face’s passive areas, indicating
optimal width to depth ratio between 3 to 7 to minimize the cutting lesser chip crushing and material adhesion on the tool active interface.
forces and facilitate the chip formation process. Fig. 2 shows the chip According to the authors, this behavior leads to lower cutting forces,
formation zone and the stress distributions for two width-to-depth ratios surface roughness, and tool edge chipping.
after the cutting force has reached a steady state. Fig. 2(a) shows that the
first microgroove at the chip-tool interface serves as a micro cutter as the 3. Cutting forces
chip flows over the rake face, resulting in highly localized pressure and
microchips curling into the microgroove. As the width-to-depth ratio Cutting forces are the important indicators of the machining process
increases from 1 to 16 (Fig. 2(b)), the microgrooves turn to be shallower that are practically related to all the process variables and the machine
and the highly localized stress concentration (at groove walls) gradually tool existing state and tool design. According to Trent and Wright
disappears. Although the microgrooves may form some local obstacles (2000), the machining process forces are relatively low compared to
for chip flow during cutting, they also play an important role in breaking other manufacturing processes such as forging and rolling. It is due to
the intimate contact between the chip and tool, thus facilitating chip the small contact areas characteristic involved in the machining oper­
flow during cutting. ations. However, the stresses associated may be higher than other
Sivaiah et al. (2020) evaluated the effect of texture patterns in the manufacturing processes. By modifying the contact areas engaged in the
rake face of a PVD coated cemented carbide tools in the form of dimples process and, consequently, the material flow, surface texturing of cut­
and dimples + grooves, in the turning of Inconel 718 under minimum ting tools becomes an effective alternative in reducing cutting forces
quantity lubrication (1:20 soluble oil at 80 ml/h). The authors found without altering the tool geometry.
that the tool texturized with dimples + grooves outperformed the tool Zhu et al. (2016) evaluated the application of surface textures in the
with dimple textures as well as the non-textured tools in relation to the form of microgrooves at the rake face of PCD coated cemented carbide
chip morphology, tool life, and surface roughness. Fang et al. (2016) tools by using ultrasonic elliptical vibration texturing method. The
evaluated the tribological performance of laser patterned grooves and textures had pitches of 200 and 400 μm and depth of 12 μm and were
dimples in cemented carbide tools using friction tests similar to the tested in the turning of an aluminum alloy. This innovative texturing
honing process. The authors found that dimples outperformed grooves process showed high potential to improve production with high effi­
regarding the hydrodynamic effects and friction coefficient. Similar re­ ciency and accuracy of surface textured tools even in ultrahard coatings,
sults were found by Fang et al. (2017b) when evaluating the frictional such as PCD. The texture pattern with lower pitch (200 μm) showed
performance of laser textured cemented carbide surfaces, using a better performance in terms of chip adhesion. Moreover, the cutting
ball-on-flat nanotribometer under linear reciprocal movement. The au­ force could be reduced to 17.1 % compared to non-textured tools.
thors found that laser patterned presented a more stable and without The better performance related to chip adhesion is also extensively
running-in period coefficient of friction compared to polished cemented found in the literature (Ghosh and Pacella, 2020). Furthermore, better
carbide. results were observed for nano (Liu et al., 2018a), self-lubricating tex­
Pratap and Patra (2020) studied the effect of surface textures at the tures (Zhang et al., 2017), and dimple texture pattern (Ahmed et al.,
rake face of PCD micro-tools in the micro-slot grinding process of BK7 2020). According to most of the authors, the main reason is linked to the
under dry, low, and high-pressure MQL (minimum quantity lubrication). reduction in chip-tool contact area. The same was observed and
explained by Su et al. (2018). An increase in chip adhesion was reported
only when using relatively bigger texture patterns (Singh et al., 2020).
Lian et al. (2018) examined the use of nanotextures in
self-lubricating cutting tools during the dry turning of AISI 1045 hard­
ened steel. Four different types of cutting tools were evaluated, a con­
ventional commercial tool (CT), a tool soft-coated with WS2 (WCT), a
textured tool (TT), and a soft-coated textured tool (WTT). The main
results are illustrated in Fig. 3. In relation to the non-textured and un­
coated tools, considerable reductions in cutting forces (Fig. 3a) were
noticed, ranging from 9 to 31% for the soft-coated tool, 8–18 % for the
textured tool, and 10–44 % for the tool with both texture and
soft-coating. In relation to the friction coefficient (Fig. 3b) at the
chip-tool interface, WCT, TT, and WTT tools outperformed the con­
ventional tool (CT) by 2~13 %, 2~7%, and 10–25 %, respectively. In
relation to the average flank wear (Fig. 3c), WTT outperformed the other
tools followed by WCT and TT tools, which indicated that the soft
coating decreased the tool wear significantly, when coupled with surface
texturing. A similar trend is also observed for the surface roughness
(Fig. 3d), with reductions in Ra for WCT, TT, and WTT as 20~30 %,
15~34 %, and 32~37 %, respectively, in relation to the conventional
tool (CT). The authors further stated that both coating and texturing
benefits were even more pronounced for the higher cutting speeds.
Fig. 2. Chip formation zone and stress distributions (groove width = 70 μm Arulkirubakaran et al. (2019) investigated the use of textured tools in
and edge distance = 50 μm). (a) width-to-depth ratio of the groove = 1, and (b) the turning of Al-5Cu-TiB2 composite, fabricated by in-situ casting. The
width-to-depth ratio of the groove = 16. Adapted from Chen et al. (2017). textures were fabricated in two patterns, areal and linear, on the rake

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 3. Machinability of the tools with different textures and SEM photos of the tools after tested. (a) CT; (b) WCT; (c) TT; (d) WTT; (e) cutting force; (f) coefficient of
friction; (g) average flank wear; (h) surface roughness. Adapted from Lian et al. (2018).

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

face of ISO K20 cemented carbide insets using electrical discharge micro-dimple presented a substantial reduction in the passive cutting
machining (EDM) process. The areal texture was composed of dimples force with no significant reduction when using the other ones.
with a size of 200 μm, and the linear textures were evaluated both Arulkirubakaran et al. (2018) studied the effect of surface textures on
parallelly and perpendicularly to the chip flow with 250 μm width and the rake face of an uncoated cemented carbide insert in the machin­
100 μm depth. The authors found a reduction in the cutting force and the ability of Ti-6Al-4 V alloy during turning under semi-solid lubrication
specific cutting energy of up to 30 % for the linear texture perpendicular (20 % MoS2 + 80 % SAE 40 oil). The EDMed surface textures consisted of
to the chip flow, as shown in Fig. 4. This reduction was explained by grooves parallel, perpendicular, and oblique to the chip flow direction
lower adhesion of the workpiece material on the tool, absence of with 250 μm width and 100 μm depth. The authors found that surface
built-up edge formation, and overall better lubrication in the chip-tool textures on the tool significantly reduced the machining forces under
interface. The tool wear got drastically reduced at perpendicular lubricated conditions. The main cutting force was reduced up to 30 % for
textured tools, especially under the lubricated condition. the grooves perpendicular to the main cutting edge because it reduced
Duan et al. (2017a) studied the use of micro-textures with a single the tool-chip contact area and enhanced the lubrication in the cutting
groove (parallel to cutting edge and fabricated by Nd:YAG laser) on the zone. The authors also found that power consumption was reduced up to
rake face of the WC/Co cemented carbide tools during dry turning of 20 % when the perpendicular groove was used. Similar results of
medium carbon AISI 1045 steel. The manufactured grooves had a width reduction in the cutting forces (of up to 38.4 %) were found with similar
of 50 μm, a depth of 13 μm, and a distance of cutting edge of 150 μm. texture pattern by Zhou et al. (2019) during wet milling of the same
The authors found that the derivative cutting causes filling of the surface Ti-6Al-4 V alloy.
textures, increasing the friction at the tool-chip interface, leading to Xing et al. (2016) evaluated three types of textures (linear grooves,
higher cutting forces and chip deformation. Vasumathy and Meena circular dimples, and rectangular dimples) fabricated by a Nd: YVO4
(2017) also evaluated grooves parallel to the main cutting edge and laser, with 10 μm depth and area density of approximately 20 % on the
found a reduction of 7.7 % in the cutting force. Gajrani et al. (2018b) rake face of cemented carbide cutting tools. The authors found that the
studied similar textures perpendicular to the cutting edge and found texture’s rectangular dimple configuration presented the smallest cut­
reductions in the cutting force ranging from 4.23 % to 10.82 % for un­ ting forces among all the cutting tools tested. However, as the cutting
coated tools and 7.31%–17.41% for coated tools. On the other hand, speed increased, the cutting force reduction’s effectiveness decreased,
according to Kang et al. (2018b), although the textures have reduced the and for the highest cutting speed, it became counteractive. The use of
cutting forces by 15 %, the grooves’ orientation did not substantially surface textures also reduced the friction coefficient for the lower cut­
influence this reduction. ting speeds (55–220 m/min) with the rectangular texture pattern, pre­
Pratap et al. (2019) used micro-EDM to texture the end face of senting the smallest friction coefficients for this cutting speed range.
polycrystalline diamond (PCD) micro-grinding tools. In addition to the According to the authors, at lower cutting speeds, the chip flow is
non-textured tools, tools with 50 μm deep and 200 μm wide benefited by the smaller contact area, but it became more ductile at
micro-dimple texture in the center of the end face and with one, two and higher cutting speeds, flowing over the textures and increasing both the
four microgrooves along the diameter of the end face, respectively, were cutting forces and the friction coefficient. Similar results regarding
also examined. The dry grinding was performed in BK7 soda-lime silicon reduction in friction coefficient, when surface textures were used, were
glass with a cutting speed of 2000 rpm and feed rate in the range of found by Aktürk et al. (2015) in flat-on-cylinder tests using a laser
25− 200 μm/min. The authors found that the tool with four micro­ textured D2 tool steel cylinder against a 6111-T4 aluminum sample.
grooves had the lowest cutting force values with a reduction of about Sarma and Rajbongshi (2020) studied the effect of μEDMed groove
35–40 % compared to the non-textured tool. The tool with a and dimple surface textures on the rake face of TiN coated cemented

Fig. 4. Comparisons of the machining forces when using the different textured tools and SEM images of textured patterns. (a) Non-textured (b) Areal (c) Linear
texture with perpendicular to chip flow direction (d) Linear texture with parallel to chip flow direction. Main cutting forces at different cutting speeds (e) dry
condition (f) lubricated condition. Adapted from Arulkirubakaran et al. (2019).

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

carbide cutting tools. The machining trials were performed amid dry respectively. Also, they had a distance from the cutting edge of 150 μm
turning of AISI D2 steel (45 HRC) under two cutting speeds (100 and and two different spacings of 60 μm and 100 μm. The hybrid texture
150 m/min), feed rates (0.05 and 0.15 mm/rev), and depth of cut (0.25 effect was more evident in the case of high cutting speed (120 m/min),
and 0.55). The authors concluded that both textured patterns resulted in when the cutting temperature was reduced by 6.9–21.7 %. Another
lower cutting and feed forces and apparent friction coefficient, work that also studied the effect of solid lubricants of MoS2 (Gajrani
compared to non-textured tools with dimple pattern, and thus, present et al. (2018a)), concluded that the workpiece temperature was reduced
improved results. by 21 % (without MoS2) and 17 % (with MoS2) when compared with
those of un-textured cutting tools.
4. Cutting temperature Arulkirubakaran et al. (2016) studied the turning of Ti–6Al–4 V alloy
using textured tungsten carbide tools with microgrooves textures on the
According to Trent and Wright (2000), the machining process costs rake face. The wire EDM textures were in parallel, perpendicular, and
are generally dependent on the material removal rate. However, the cross pattern to that of chip flow orientations, with 250 μm width and
removal rate increase is usually accompanied by an increase in the 100 μm depth. In a similar way of the previously discussed work of Sun
temperature at the chip-tool-workpiece interfaces. The enormous et al. (2016), a mixture of MoS2 with SAE 40 oil (80:20) was used as a
amount of energy involved in chip formation is converted into heat and semi-solid lubricant. The authors concluded that, in general, the textures
acts as a source of many machining challenges related to workpiece reduced the cutting temperatures of the process as they reduced the
quality, tool life, and process productivity. The use of cutting tools with contact area. This further reduced friction forces, improved the lubri­
surface textures represents a possibility of reducing the heat generation cation in the tool-chip contact interface with the perpendicular pattern,
during the process and helping to dissipate it more efficiently, thus and finally presented the overall best results.
improving the machinability. Fang and Obikawa (2017) evaluated microtextures’ effect on the
Sawant et al. (2018) studied the influence of spot and dimple textures flank face of cemented carbide PVD-coated tools with TiAlN. The tex­
manufactured by micro-plasma transferred arc powder deposition pro­ tures were manufactured using laser irradiation on the tools’ flank face,
cess, on the rake face of grade T-42 HSS cutting tools in the dry turning with the parallel, perpendicular, pit, dot, and crosshatch patterns, as
of Ti-6Al-4 V titanium alloy. The use of dimple-textured HSS tools shown in Fig. 6. The texture width and interval were 50 μm and a length
resulted in better performance regarding cutting and thrust forces, tool ranging from 50 μm to 2200 μm, respectively. The machining trials
temperature, flank wear, and surface roughness for the evaluated cut­ consisted of turning of Inconel 718 alloy using an emulsion with 10 %
ting conditions. As illustrated in Fig. 5, the cutting temperatures increase concentration as coolant, under a constant cutting speed of 120 m/min,
for both textured and non-textured tools with the rise in cutting speed. feed rate of 0.1 mm/rev, and depth of cut of 0.5 mm. The use of surface
The temperatures for the spot and dimple texturized tools are around 12 textures reduced the cutting temperatures as it increased the shear an­
% and 4% lower, respectively, when compared to the non-textured tool. gles, which improved the process’s tribological conditions. The results
Because of their shapes, the spot textures lead to an early separation of further indicated that the textures’ height or depth strongly influenced
the chip from the rake face, enhance the convective heat transfer of the its fin behavior, and thus, the thermal conditions of the cutting region.
process, and thus, help to improve the tool life during machining. Rajbongshi and Sarma (2019) compared the performance of dimple,
Song et al. (2017) used micro-EDM to fabricate textured groove, and non-textured coated cemented carbide tools model SNMG
micro-dimples on the rake face of WC/TiC/Co cemented carbide tools, 120408-KM3215, in dry turning of AISI D2 steel. The textures with a
with an average of 150 μm diameter and 200 μm depth. To further diameter of 120 μm, depth of 20 μm, and distance from the cutting edge
improve the tribosystem, graphite was embedded into the of 50 μm, were fabricated on the flank face of the tools using μ-EDM. The
micro-dimples to form self-lubricating tools. The textured tools were dimple textured tools resulted in lower average cutting temperatures
tested during the dry turning of AISI 1045 hardened steel and were than groove textured and non-textured tools. Similar results were pre­
compared with non-textured tools. The textured tool’s cutting temper­ sented by Lian et al. (2018), where the cutting temperatures were
ature embedded with graphite was 15–20 % lower than that of the lowered by 12–16% with coated and textured tools compared to un­
conventional carbide tool. The authors explained that the cutting tem­ coated tools.
peratures were lowered because of the lower contact length and friction Li and Zhang (2019) studied textured cemented carbide tools in dry
between the chip and the tool, caused by the surface textures with turning of northeast China ash wood (Fraxinus spp.). The textures were
embedded graphite. fabricated on the tools’ rake face with dimple shape with diameters
Sun et al. (2016) fabricated microgrooves, micro-dimples, and ranging from 80 to 200 μm, depth of 10 μm, and texture density ranging
hybrid textures via Nd:YAG laser on the rake face of carbide tools with a from 5 to 30 %. The authors reported that the average cutting temper­
solid lubricant (MoS2) applied to fill the micro-textures. They further atures decreased with surface textured tools compared to non-textured
examined these textures in the dry turning of AISI 1045 steel. The tex­ ones, although the peak temperatures did not present a significant
tures had a width and diameter of 40 μm and depth of 50 μm, decrease. According to the authors, the reduction in the average cutting

Fig. 5. (a) Temperature of the spot-textured, dimple-textured, and non-textured HSS tools during turning of Ti-6Al-4 V at different cutting speeds; (b) dimple texture;
(c) spot Texture (Sawant et al., 2018).

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 6. Laser-irradiated micro-textures (a) parallel (b) perpendicular (c) pit (d) dot (e) crosshatch (Fang and Obikawa, 2017).

temperatures can be attributed to a reduction in the contact area be­ cooling at high cutting speeds (Carvalho et al., 2019). At low cutting
tween the chip and the tool’s rake face, which reduced the cutting and speeds the cutting fluid has a greater chance to penetrate into the
friction forces. The best results were found for the dimples with 120 μm chip-tool-workpiece interfaces and exerts its lubricant function prop­
diameter, 10 μm depth, and texture density of 20 %. erly. There are less chances for the lubricant action at high cutting
Vignesh et al. (2020) evaluated the effects of surface textured tools in speeds, and the temperatures are usually high and the cutting fluid is
dry turning of AISI 4340 steel. The textures were manufactured using called upon to exert its cooling function.
laser marking technique and placed in the rake face of TiN coated In general, the most significant function of these cutting fluids is
cemented carbide tools. The pattern chosen by the authors was the found as a lubricant at low cutting speeds and as a cooling medium at
dimple with diameters of 80, 90 and 100 μm, depths of 60 and 70 μm, high cutting speeds. The study of the effect of cutting fluids with the
and density ratios ranging from 0 (non-textured tools) to 45 %. A group surface texture of the tools aims to improve the lubricity of the tribo­
of tools had the patterns coated with MoS2 for enhancing the tribological system in question, thus helping to reduce the severity of interactions at
behavior at the rake face. The authors found that the average heat the cutting interface.
generation was lower when the tool was textured and coated with MoS2. Liu et al. (2019b) evaluated the performances of non-textured and
It was due to lower friction and wear at the rake face. The authors found micro-textured grooves on uncoated WC-10Ni3Al and WC-8Co tools in
that a dimple with diameter of 90 μm, a depth of 60 μm, and a density both dry and wet milling (emulsion) of Ti6Al4V alloy. The textures were
ratio of 35 % had better morphology related improvements in the manufactured using a pulsed fiber laser, perpendicular to the chip flow
machinability. direction with a distance of 100 μm to the cutting edge and 100 μm of
Patel et al. (2020) evaluated the effects of microtextured tools in dry spacing. The authors found that micro-textures reduced the adhesion on
turning of Ti6Al4V titanium alloy. The patterns were made using the rake face at the lower cutting speed of 50 m/min. At higher cutting
micro-EDM at the rake face of an uncoated cemented carbide tool. The speeds, the textured tools outperformed the non-textured ones, espe­
pattern designs investigated were microgrooves perpendicular, parallel, cially in the wet condition. The main reason for this lied that these
diagonal, and cross-patterned to the main cutting edge. The evaluated textures acted as a lubricant reservoir to the cutting fluid (Fig. 7), thus
microtextures had cutting width ranging from 50 to 100 μm, spacing of reducing the cutting temperature and increased tool life.
15, 50, and 100 μm, and distance from the main cutting edge of 10, 20, Grguraš and Pušavec (2019) evaluated the performance of eight
and 30 μm. The authors found that the cutting forces significantly different rake face texturing patterns in cemented carbide inserts. The
increased as the distance of the pattern to the cutting edge and depth machining trials were performed in the turning process using a CK45
increased, thus, resulted in substantial rise in wear rate and cutting medium carbon steel as workpiece material. Although the surface
temperatures. texturing did not influence the machining performance compared to
non-textured tools, the texturing had a significant influence on the
5. Lubrication machining forces, with the best results being found for the parallel
textured tools. The authors explained the better performance of the
According to Astakhov (2006), tribology can be understood as the textures parallel to the main cutting edge in terms of the better pene­
science and technology that studies the interaction of surfaces in relative tration via the cutting fluid and their role as a micro-reservoir for
motion, including friction, wear and lubrication. Many of the phenom­ emulsion, which improves the cooling and lubrication of the cutting
ena observed in machining can be explained by the tribological in­ interface.
teractions of the triad workpiece-tool-chip. The usage of cutting fluids is Zhou et al. (2019) studied the effectiveness of surface texturing on
one of the most common strategies for tribological control systems, the rake face, parallel to the main cutting edge of uncoated (K10)
including in machining (Da Silva et al., 2019). During the shearing cemented carbide tools with 10 mm diameter during down end milling
process in metal cutting, a considerable amount of heat is generated due of Ti6Al4V alloy. The textures were fabricated using Nd: YAG laser with
to plastic deformation and friction. In general, the most significant 100 μm of width, 100 μm of spacing, and 50 μm of depth. The
functions of a cutting fluid are lubrication at low cutting speeds and machining trials were conducted using conventional and nanofluids

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 7. Functioning mechanisms of the micro-textures proposed by Liu et al. (Liu et al., 2019b).

containing Fe3O4 nanoparticles with 80 ηm of diameter, applied under tools using magnetron sputtering. The authors found that the combi­
MQL condition. The tool wear and workpiece material adhesion were nation of surface texturing and soft coating resulted in the smallest
dramatically reduced under the influence of the combination of cutting forces, temperatures, friction coefficient, and material adhesion
texturized tool and MQL nanofluid compared to the other cutting con­ in the tool-chip interface. The surface textures lead to vacant areas under
ditions. Compared to the non-textured tool with conventional cutting the counter body’s surface (chip undersurface) that are filled with air in
fluid, the tool wear rate was lowered down to 63.3 %. The authors dry cutting. This can further result in increased shear deformation and
explained that this reduction is due to the better wettability and reduction of tool/chip contact length compared to a non-textured tool
spreadability of the nanofluids in the texturized surface, promoting a (as shown in Fig. 8). The reduced tool/chip contact length contributes
more stable lubrication film in the tool-chip interface. towards reducing the real contact area of the tool/chip interface, which
Zhang et al. (2017) investigated the effects of a WS2 solid lubricant further causes a decrease in friction. The textures’ presence improved
film and femtosecond laser texturing on the rake face of PVD TiAlN the lubrication and made the WS2 deposited layer last for a longer
coated cemented carbide tools. The surface texture was fabricated with a period compared to the untextured tools. The use of surface texturing
1.0 mm2 of area on the tools’ rake face, 150 μm away from the cutting was also responsible for a stronger adhesion of the WS2 deposited
edge. The WS2 lubricant layer was deposited on untextured and textured coating since it forms a barrier preventing the WS2 slipping, enhances

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 8. Schematic mechanism of improved cutting performance due to WS2 soft-coatings and femtosecond laser-textures on TiAlN coated tool (Zhang et al. (2017).

the TiAlN reactivity, and highlights a good interaction among the burr height, and chip size. The authors further stated that the graphite
techniques. coated drills had the best results for improved tool life.
Orra and Choudhury (2018) investigated the effect of three different Singh et al. (2020) evaluated the effect of graphene-assisted MQL in
geometrically shaped textures impregnated with MoS2 dry lubricant on the turning process of the Ti6Al4V alloy using textured uncoated
the rake surface of Al2O3 + TiC ceramic cutting inserts during dry cemented carbide tools. The textures were manufactured at the rake face
turning of AISI 4340 hardened steel. The authors evaluated textures, of the tools using a femtosecond laser with a dimple pattern of 80 μm
fabricated by an epilog laser carrying grooves in an elliptical shape, as diameter, 50 μm depth, and 150 μm of distance to the cutting edge. The
well as grooves parallel and perpendicular to the chip flow. The textures’ machining trials were performed under dry, MQL (using canola oil), and
width was between 200 and 215 μm and the gap between the textures MQL using graphene nanoparticles at 1.0 wt% in concentration. The
was between 150 and 215 μm. Some tool textures were further MQL was supplied at 6 bar of pressure and 120 ml/h of flow rate. The
impregnated with MoS2 dry lubricant. The microtextures successfully authors found that the use of graphene nanoparticles improved the
reduced cutting forces, leading to lower flank and nose wear values for system’s lubricity, outperforming the other cutting conditions in rela­
all evaluated cutting speeds. The cutting tools impregnated with MoS2 tion to chip curl radius, surface roughness, and tool wear.
presented lower effectiveness at higher cutting speeds. This happened
due to the higher cutting temperatures generated by the higher cutting 6. Surface integrity
speeds, in which the MoS2 impregnation became unstable and thus, lost
effectiveness. According to the authors, the improvement in the According to Shaw and Cookson (2005), surface integrity involves
machinability was noticed at the application of microtextures (that aspects such as surface finish, crack formation, chemical changes,
reduced the tool-chip contact length) and MoS2 solid lubricant thermal damage, and surface stresses. Meeting the specifications for the
impregnation (that spread on the rake face of the tool) creating a dry parameters described above is a major challenge as they are causally
lubricant medium, which further improves tool life. linked to the applicability of the product. Decreasing the volume of
Peña-Parás et al. (2020) studied the effects of interaction between material removed is generally associated with improved surface integ­
surface textured tools and nanolubricants in the milling of AISI 1018 rity and is often not productively advantageous. By influencing the chip
steel under flood lubrication. The surface patterns were made by laser formation process, cutting forces, machining temperature, and lubricity,
texturing in the form of micro circles and channels in the rake face of surface textures’ application improves surface integrity.
CVD TiAlN coated cemented carbide inserts. The fluid was composed of Rajbongshi et al. (2018) used a micro-EDM to fabricate grooves on
a dispersion of montmorillonite nanoclay particles in an emulsion (14 % the flank face of a CVD TiCN + Al2O3+TiN coated carbide tools, which
oil and 86 % water) at 0.13 wt% concentration. The authors found that were orthogonal to the main cutting edge. The grooves were distanced in
in addition to the role of textures in increasing the machinability with 50 μm from the cutting edge, with 200 μm length and spacing of 50 μm
respect to load and surface roughness, the nanoparticles’ synergic effect between each other and 20 μm of depth. Machining experiments were
also enhanced the machinability, especially for the microchannel conducted in dry turning of AISI D2 steel (45 HRC) using both textured
pattern. and non-textured tools. The results showed that the surface texturing
Kumar Mishra et al. (2020) evaluated the effect of laser textured helped decrease the flank wear, resulting in a substantial improvement
tools under MQL and nano-MQL environments during the turning of of surface finish. The machined surface produced by the textured tool
Ti6Al4V alloy. The textures were manufactured in the rake face of un­ was glossy, when compared to the non-textured tool (Fig. 9). The
coated cemented carbide tools using a nanosecond pulsed laser with thickness and hardness of the white layer produced by the textured tools
dimples of 60 μm diameter. The textures were evaluated under dry, were also lowered. The authors found that due to the high-temperature
MQL, and nano-MQL environments, using a 1:10 sunflower emulsion as generation in the case of non-textured tool, the surface topology can be
MQL lubricant and 0.5 wt% of Al2O3 as nanoparticle additive. The au­ changed. However, it is observed that texturing helps to generate a
thors found that both MQL and nano-MQL resulted in reduced cutting better surface compared to surface produced by the non-textured tools.
and thrust forces as well as apparent friction coefficient. The results for Palanisamy et al. (2019) studied the machinability during dry
the nano-MQL were further enhanced by the formation of a tribofilm of turning of 17− 4 PH hardened stainless steel using cryo-treated cemen­
deposited/agglomerated nanoparticles at the texture patterns, espe­ ted carbide textured tools. The tools were textured using wire-EDM with
cially at the lower cutting speeds. grooves on the rake face, parallel to the chip flow direction. The tool
Dheeraj et al. (2020b) studied the effects of tool surface texturing in inserts were kept in a cryogenic chamber for 24 h and then tempered at
aluminum drilling. The textures were manufactured in the drill flute of 200 ◦ C for 2 h. The authors found that the cryo-textured tools led to
an uncoated cemented carbide drill using laser micromachining. The lower cutting forces, vibrations, and surface roughness than the
machining trials were performed under dry, blasocut, graphite, and non-textured tools. In the same line of investigation, Rajbongshi and
MoS2 atmospheres. The textures were filled with graphite, MoS2, and Sarma (2019) used micro-EDM to fabricate textures (dots and grooves)
MoS2+graphite. The authors found that textures filled with solid lubri­ in cemented carbide cutting tools and tested them in the machining of
cants resulted in better hole accuracy, cylindricity, surface finish, lower hardened AISI D2 steel. They also found that in terms of surface

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 9. SEM images of machined surface of AISI D2 steel by (a) non-textured tool (b) textured tool; at vc =100 m/min, f =0.05 mm/rev, doc =0.25 mm (Rajbongshi
et al., 2018).

roughness, the textured tools outperformed the non-textured ones. machining process of GCr15 hardened steel. The textures were fabri­
Liu et al. (2019a) investigated new designs of curvilinear micro­ cated by laser machining with two sets of dimples, one with 80 μm
grooves on the rake face of coated cemented carbide inserts in the diameter and 250 μm of spacing, and other with 120 μm diameter and
machining of 17− 4PH stainless steel. Three types of microgrooves were 350 μm of spacing. The authors found that micro-hole textured tools
designed on tool rake face: microgrooves with linear surface and bottom improved the machined surface quality by reducing the surface rough­
cross-sections (LSB), microgrooves with curvilinear surface and linear ness when compared to non-textured tools, with the smaller textures
bottom cross-sections (CSLB), and microgrooves with curvilinear surface (80 μm of diameter), presenting the best results. Surface texturing can
and bottom cross-sections (CSB). Wire-EDM manufactured the textures also achieve surface exhibiting compressive stresses, known for their
with a groove width of 50 μm, spacing between grooves of 50 μm, and resistance towards crack propagation. The effect of the micro-hole tex­
groove depth of 30 μm. The textures’ behavior was compared in the dry tures on the workpiece roughness was also explained in terms of residual
turning process by 3D FEM. The textured tools showed better cutting stress of the machined workpiece surface, as shown in Fig. 11. The
performance than the non-textured tools in both FEM simulations and micro-holes on the tool surface improve the tools’ cutting performance
machining trials. The use of curvilinear micro-grooved tools improved and cause the workpiece to possess and display compressive stresses,
the chip formation process and reduced forces, temperature, leading to a which further improves the fatigue performance of the part and reduces
better surface integrity. The 3D FEM simulation confirmed that, in the roughness of the part surface, leading to an improved quality of the
comparison to non-textured and linear micro-grooved tools, the curvi­ component.
linear microgrooves on tool rake face were more effective in promoting S, N. and G.L, S. (2018) evaluated the drilling process of Ti6Al4V
chip curling, reducing tool-chip friction, chip thickness ratio, cutting alloy at different lubrication conditions (dry, wet, and MQL) using un­
forces, and temperature, and thus, leading to better surface integrity. In coated cemented carbide drills with a diameter of 8 mm. The textures
addition, curvilinear microgrooves induced tool stress dispersions and were fabricated by Nd-YAG laser micro-machining, in the form of cir­
weakened the stress concentration on cutting edges (Fig. 10), which is cular micro-dimples with an average diameter of 90 μm, depth of 60 μm,
beneficial for suppressing cutting tool wear and fracture/chipping. and density coverage area of 35 %. The textures were placed on the
Li et al. (2019) used dry turning tests and finite element analysis to drills’ flute and margins, with a distance of 30 mm from the tool-tip. The
compare the textures fabricated on the rake face of PCBN tools, in the machining revealed a significant reduction in titanium deposited on the

Fig. 10. Effect of micro-grooved tool types on tool stress distributions in rough turning (Liu et al., 2019a).

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 11. Residual stress on the workpiece after machining with a) d = 80 μm micro-hole tool, (b) d = 120 μm micro-hole tool, and (c) non-textured tool (Li
et al. (2019).

tool by 44 % in the margin textured tool, compared to the non-textured under dry condition using the non-textured tool. In the case of textured
tool. The lower titanium content is a clear indication of the reduction of tools, reduction in sliding friction due to a reduction in contact length
work material adhesion on the tool surface due to micro-scale textures. and micro-pool lubrication effect favored faster heat dissipation,
The use of surface textured tools leads to lesser surface defects in the resulting in better quality surfaces.
drilled holes. In MQL and wet conditions, the surface textured mini­ Chen et al. (2019a) investigated the dry milling of carbon fiber
mized the burr formation in the holes’ exit due to enhanced heat dissi­ reinforced plastics laminated at different orientations (0, 45◦ , 90◦ and
pation in the cutting interface. 135◦ ). They evaluated the effect of textures on the rake face parallel and
S, N. and G.L, S. (2018) also performed SEM analysis of the rake perpendicular to cemented carbide milling cutters’ main cutting edge.
surface as shown in Fig. 12. Sub-surface defects such as material side The authors found that the surface roughness was not significantly
flow, chip adhesion, and smearing material were observed under all affected by the surface texture, with the fiber orientation being the most
machining conditions tested. Such defects were found to be more severe significant factor regarding this variable. However, the textured tools

Fig. 12. SEM image of sectioned hole surface at the exit zone under dry, wet and MQL condition (S, N. and G.L, S., 2018).

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

presented smaller chip segments, as it changed the deformation textured grooves lower edge (Fig. 13). The phenomenon could remove
behavior of the chip fibers and had a pronounced impact on fiber burr hard inclusions from the tool-workpiece interface to keep the unworn
formation on the machined surface. The tools with textured grooves face safer against the hard inclusions scraping. That was the reason why
parallel to the main cutting edge were more effective in reducing the textures on the flank face could enhance flank-wear resistance.
burr length and tearing phenomenon. The author further stated that the Liu et al. (2018a) compared cemented carbide tools (WC + 6%Co)
surface texture acted as a storage for the carbon fiber fragments, pre­ with the flank face polished, nano-textured, polished, TiAlN coated and
venting the fiber chip’s slippage on the rake face of the tool. Similar nano-textured, and TiAlN coated tools in the dry turning of green Al2O3
results were found by Ghosh and Pacella (2020) regarding the perfor­ ceramic. The textures were manufactured using a titanium sapphire
mance of diamond (PCD) cutting tools in the dry turning of Al-6068 femtosecond laser and were parallel to the main cutting edge. The tex­
alloy. The authors explained that this texture direction leads to a tures distance was 75 μm from the main cutting edge and possessed a
lower contact area between the chip and the tool, and thus, improves the width of 0.6 μm and depth 0.15 μm. The authors concluded that the
chip flow and lowering the adhesion. nano-scale textures significantly affected the adhesion force of TiAlN
Sivaiah and Bodicherla (2020) studied the effect of surface texturi­ coating and tool substrate. Both tools with nano texture, with and
zation on tool wear and surface roughness during the turning of AISI without coating, were noticed with a greater flank-wear resistance when
52100 steel. The tools were textured at the rake face using fiber laser in compared to the non-textured tools. The textured and coated tool
two patterns: dimples and 45◦ grooves inclined to the main cutting edge. demonstrated the best overall results. The authors reported that even
An emulsion (1:15 ratio), as MQL mist at a flow rate of 100 ml/h, was after the coating detachment, the surface textures exhibited “derivative
used in the machining tests. The authors found a direct correlation be­ cutting", resulting in the protection of the tool surface from further
tween the cutting velocity and feed rate with the tool flank wear. The abrasion.
surface roughness had a direct correlation with the feed rate and inverse Cui et al. (2018) evaluated the performance of four different patterns
correlation with the cutting speed. The authors observed that less BUE of microtexture based on dung beetle and shark skins (Fig. 14), in the
was formed when using the 45◦ grooves as surface texture pattern, intermittent turning of AISI 52100 hardened steel using ceramic
resulting in a better surface finish than the dimple texture. (Al2O3/(W,Ti)C) tools. The textures were fabricated on the rake face of
the tool using nanosecond laser machining. The diameter and depth of
7. Tool life and wear the microdimples used were of 50 μm and 20 μm, respectively. The
authors found that the increase in cutting length ratio resulted in larger
For bringing a significant reduction in the production cost, tool life tool performance indicators for each texture pattern. The skin-shark
acts as one of the most important parameters in the machinability texture TE (Fig. 14) presented the most significant values of this indi­
assessment. According to Astakhov (2006), the severity of general cator. These higher indicator values mean that the microtexture was the
machining tribosystems causes more frequent tool changes than other most beneficial parameter for improving the tool life. Similar results
manufacturing systems. The same increases the materials cost and un­ were found by Singh et al. (2019) in the turning of AISI 4340 hardened
productive times. This section deals with the understanding and mea­ steel under MQL lubrication, when the application of textured tools
sure of the impact of surface texturing on tool life. increased the tool life up to 108 %.
Mishra et al. (2018b) evaluated two different PVD coated (AlTiN and Alagan et al. (2019) studied the effects of three different
AlCrN) cemented carbide (WIDIA: K-grade CNMA120408) laser micro-textured patterns of round and square dimples (Fig. 15) on both
textured tools in the dry turning of Ti6Al4V alloy. The novel chevron rake and flank face of round uncoated cemented carbide inserts during
textures on the tools rake face were fabricated using Nd:YAG nano­ the turning of Inconel 718, under high-pressure coolant lubrication. The
second fiber laser at 100 μm distance from the cutting edge. The authors textures were fabricated using Nd:YAG laser machining with 250 μm of
found that laser textured tools resulted in better coating deposition with spacing and pitch, 100 μm of diameter and depth, and 200 μm distance
reduced microcavities and macroparticles. The better mechanical from the main cutting edge. According to the authors, the textured tools
interlocking provided by the textured surface resulted in further adhe­ did not significantly impact the tool-chip contact area. The tools with
sion to the coating. The authors also observed that better coating leads to square dimples on the flank face and circular dimples on the rake face,
reduced cutting and thrust forces, and lower flank wear, especially for presented the higher wear resistance with 30 % higher tool life than the
the AlCrN coated tools. Arulkirubakaran et al. (2016) in their experi­ regular insert.
ments, also found that the use of surface texturing improved the tool Feng et al. (2019) evaluated different morphologies of
wear resistance amid the turning of Ti6Al4V. micro-texturing on the rake face of ceramic self-lubricating inserts in the
Zhang et al. (2019b) evaluated the use of nanotextured tools in dry dry turning of AISI 40Cr steel. The textures were fabricated with three
milling of AISI 316 stainless steel workpiece. The textures were manu­ positional distribution levels, with a width of the groove and space be­
factured by selective laser melting (using a femtosecond laser) in the tween textures ranging from 0.1 to 0.2 mm. During machining with the
substrate of cemented carbide tools. The tool form placed on the rake groove textured tools, the authors identified a secondary cutting phe­
face consisted of ripples with 40–160 ηm depth and a period range of nomenon provided by the groove patterns’ edges. The textured tools
400–600 ηm, and was 150 μm away from the cutting edge. After the presented here reduce the cutting forces and workpiece material adhe­
substrate’s texturing, the tools received a PVD TiAlN coating with sion, resulting in reduced tool wear.
3 ± 0.5 μm of thickness. The authors found that the nanotextures Feng et al. (2019) further stated that the groove width significantly
enhanced the coating adhesiveness and increased its critical load from influenced the tool wear. It was observed that the degree of damage of
57 to 73 N when scratched with a diamond Rockwell C stylus. The main MSTW-3 tool was more serious than that of the MSTW-2 tool, as shown
wear mechanism observed for both textured and untextured tools was in Fig. 16. Additionally, in Fig. 16c and d, a white mark is clearly seen on
the adhesive wear. The textured tools outperformed the non-textured the microtexture’s edge. This white mark is a secondary chip residue
ones in terms of cutting forces and temperature, surface roughness, which was retained during chip impact. This further indicates that the
and tool wear due to the coating’s improved adhesiveness promoted by microtexture cracking damage was due to chip impact. With an increase
the texturing of substrate. in the groove width, the secondary cutting phenomenon was aggra­
According to Liu et al. (2018b), the tool wear could be improved with vated, and the microtexture structure’s strength decreased. Concerning
supplementary abrasive action of hard particles trapped in the texture the cutting impact, the aforementioned phenomena caused damage to
grooves, which further avoids any additional inclusion between tool and the microtexture and adversely affected (reduced) the tool life.
the workpiece, and thus, saves the tool face from further scraping. Pacella et al. (2019) studied the effect of three different texture
Additional cutting action on the hard inclusions took place along the patterns on PCD tools’ wear in dry turning of 6082 aluminum alloy. The

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 13. SEM images of the texture groove on the flank-face of WT-3 tool after cutting a length of 1100 m, (a) texture groove, (b) the lower edge of the groove, (c) the
top edge of the groove, (v =120 m/min, ap =0.8 mm, and f =0.051 mm/r) (Liu et al., 2018b).

Fig. 14. (a) Design process of microtexture pattern; typical microtexture of different patterns (b) arrays of microdimples - TB; (c) skin-shark patter - TC; (d) hybrid
array of microdimples and grooves equally distributed – TD; (e) hybrid array of microdimples and grooves non-equally distributed – TE. Adapted from (Cui
et al., 2018).

Fig. 15. (a) Illustration of the textured round insert; and (b) SEM micrograph of the insert at the cutting edge (Alagan et al., 2019).

tools evaluated had a 0.5 mm diamond layer over a cemented carbide of surface textures (square, parallel and perpendicular) in turning
substrate and were textured using fiber laser. The textures were fabri­ operation of AISI 304 stainless steel. The textures were manufactured
cated on the tool’s rake face in the form of parallel and perpendicular using a femtosecond laser in the rake face of an uncoated cemented
grooves. The grooves were maintained at an acute angle in relation to carbide tool (WC + 6%Co). The authors found that the squared textured
the chip flow direction, with 261 ηm of depth, 7 μm of width, and a pitch patterns presented significant reduction in relation to the coefficient of
of 50 μm. The authors reported that the textured tools presented a friction, cutting, and thrust forces. The textured patterns significantly
reduction in the crater wear and lowered the cutting forces compared to influenced the chip flow, especially in the square texture, which stabi­
the non-textured. The authors further stated that the tools with grooves lized the built-up edge formation. The same further results in improved
parallel to the chip flow, presented a better anti-adhesive effect, surface finish by 54–68 % and flank wear by 41–78 %.
reducing the aluminum stiction and the tool-chip contact area, and
resulting in reduced cutting temperature and BUE formation.
Ahmed et al. (2020) evaluated the performance of different patterns

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Fig. 16. Wear profiles on the rake faces of microtextured tools with different groove widths (a-b) MSTW-2 and (c-d) MSTW-3 after cutting for 5 min (Feng
et al. (2019).

8. Conclusions it can not only change the texture capacity to store and deliver the
lubricant but can also act as micro-bearings. As demonstrated by Fang
During this review, the state of the art of various effects of tool and Obikawa (2017), smaller texture-patterns also tend to increase the
texturization has been considered. The relevant results obtained from system wettability by increasing its lubrication properties.
the statistics have been highlighted. The reviewed papers under Fig. 17 summarizes the work materials reported in this paper with
consideration are from 2016 onwards, thus, allow the evaluation of the corresponding papers listed in Table 1. Almost 80 % of the papers
current trends in this field. Moreover, the unidentified areas requiring investigated the texture effects on hardened/high alloy steel, Ti alloys
research have been identified and highlighted. (mostly Ti6Al4V), carbon/low alloy steel, and Al alloys. This was ex­
In general, the parameters with more influence on chip formation, pected as they are the most widely employed materials in engineering.
and consequently on the machinability, are the texture width (Feng The machining processes of Ni superalloys, stainless steels, and com­
et al., 2019) and direction (Arulkirubakaran et al., 2019). However, posites remain as some of the gaps of knowledge in this field.
according to Mishra et al. (2018a), the texture density is the parameter Fig. 18 summarizes the machining processes used in the papers
with more influence on the cutting forces, since it directly influences the reviewed here to assess the effects of surface texturing in a system’s
areas of seizure and slipping in the secondary shear zone at the rake machinability, with the corresponding papers listed in Table 2. The
surface. The reason lies in the generation of a smaller contact area be­ turning process was overwhelmingly the process of choice in the
tween the chip and the tool due to higher density. However, an excessive machinability assessment (Fig. 18) of the surface textures. This data is of
increase in the density can lead to accelerated tool wear since it favors particular concern because while taking the previous reviews into ac­
the derivative cutting (Duan et al. (2017b) This further increases the count, the lack of studies on surface texturing effects on other processes
friction between the tool and the surface, since the surface inside the
texture is usually rough (Patel et al., 2019). In relation to dimple tex­
tures, according to Yang et al. (2020), the diameter is the most influ­
ential variable among most of the machinability output parameters.
The effects of surface textures under dry cutting are inferior when
compared to any kind of lubricated conditions, such as flood (Pang et al.,
2018), MQL (Sivaiah et al., 2020), flood with nanoparticles (Peña-Parás
et al., 2020), as well as self-lubricated textures (Xing et al. (2018). The
increase in lubrication improves the efficiency and functional perfor­
mance of the textures. The texture depth is a key point regarding its
effects in the lubrication of tribosystem (Fang and Obikawa, 2017), since Fig. 17. Workpiece materials reviewed in this paper.

15
A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Table 1 Table 2
Discretization of the machined materials. Discretization of the machined process.
Hardened / High (Li et al., 2019), (Xing et al., 2018), (Pan et al., 2018), ( Turning (Singh et al., 2019), (Patel et al., 2019), (Palanisamy et al.,
Alloy Steel Gajrani et al., 2018b), (Cui et al., 2018), (Zhang et al., 2019), (Mishra et al., 2019), (Liu et al., 2019a), (Lian et al.,
2017), (Song et al., 2017), (Sharma and Pandey, 2016a), ( 2019), (Li et al., 2019), (Ge et al., 2019), (Gajrani et al., 2019), (
Sarma and Rajbongshi, 2020), (Singh et al., 2019), (Patel Feng et al., 2019), (Dhage et al., 2019), (Arulkirubakaran et al.,
et al., 2019), (Palanisamy et al., 2019), (Ge et al., 2019), ( 2019), (Xing et al., 2018), (Su et al., 2018), (Sawant et al., 2018),
Rajbongshi et al., 2018), (Orra and Choudhury, 2018), ( (Rajbongshi et al., 2018), (Pang et al., 2018), (Pan et al., 2018), (
Lian et al., 2018), (Kumar and Patel, 2018), (Kim et al., Orra and Choudhury, 2018), (Mishra et al., 2018b), (Mishra
2016), (Rajbongshi and Sarma, 2019), (Vignesh et al., et al., 2018a), (Liu et al., 2018b), (Liu et al., 2018a), (Lian et al.,
2020), (Sivaiah and Bodicherla, 2020), (Klein et al., 2017), 2018), (Kumar and Patel, 2018), (Kang et al., 2018b), (Kang
(Zhang et al., 2019a), (Fang et al., 2016), (Fang et al., et al., 2018a), (Hao et al., 2018), (Gajrani et al., 2018b), (Gajrani
2017b) et al., 2018a), (Durairaj et al., 2018), (Cui et al., 2018), (
Ti Alloy (Zhou et al., 2019), (Mishra et al., 2019), (Yang et al., Arulkirubakaran et al., 2018), (Zhang et al., 2017), (Wei et al.,
2018), (Su et al., 2018), (Sawant et al., 2018), (S, N. and G. 2017), (Vasumathy and Meena, 2017), (Sugihara et al., 2017a), (
L, S., 2018), (Mishra et al., 2018b), (Mishra et al., 2018a), ( Su et al., 2017), (Song et al., 2017), (Sasi et al., 2017), (Liu et al.,
Li et al., 2018), (Hao et al., 2018), (Arulkirubakaran et al., 2017), (Li et al., 2017), (Jesudass Thomas and Kalaichelvan,
2018), (Su et al., 2017), (Niketh and Samuel, 2017), (Li 2017), (Feng et al., 2017), (Fang and Obikawa, 2017), (Duan
et al., 2017), (Arulkirubakaran et al., 2016), (Liu et al., et al., 2017b), (Duan et al., 2017a), (Chen et al., 2017), (Xing
2019b), (Mishra et al., 2020), (Patel et al., 2020), (Yang et al., 2016), (Sun et al., 2016), (Stoeterau et al., 2016), (
et al., 2020), (Singh et al., 2020), (Zhao et al., 2020) Arulkirubakaran et al., 2016), (Sharma and Pandey, 2016a), (
Carbon / Low Alloy (Lian et al., 2019), (Gajrani et al., 2019), (Dhage et al., Rathod et al., 2016), (Kim et al., 2016), (Dinesh et al., 2016), (
Steel 2019), (Pang et al., 2018), (Gajrani et al., 2018a), ( Liu et al., 2019b), (Alagan et al., 2019), (Duan et al., 2019), (
Arumugaprabu et al., 2018), (Sugihara and Enomoto, Rajbongshi and Sarma, 2019), (Grguraš and Pušavec, 2019), (
2017), (Feng et al., 2017), (Duan et al., 2017b), (Duan Ahmed et al., 2020), (Mishra et al., 2020), (Sarma and
et al., 2017a), (Chen et al., 2017), (Sun et al., 2016), (Duan Rajbongshi, 2020), (Vignesh et al., 2020), (Ghosh and Pacella,
et al., 2019), (Grguraš and Pušavec, 2019), (Peña-Parás 2020), (Patel et al., 2020), (Sivaiah and Bodicherla, 2020), (
et al., 2020), (Qi et al., 2020), (Feng et al., 2019; Zhao Sivaiah et al., 2020), (Singh et al., 2020), (Qi et al., 2020), (Zhu
et al., 2020) et al., 2016)
Al Alloy (Kang et al., 2018b), (Kang et al., 2018a), (Durairaj et al., Milling (Zhou et al., 2019), (Chen et al., 2019a), (Yang et al., 2018), (Li
2018), (Wei et al., 2017), (Sugihara et al., 2017b), (Sasi et al., 2018), (Arumugaprabu et al., 2018), (Sugihara et al.,
et al., 2017), (Kawasegi et al., 2017), (Jesudass Thomas 2017b), (Sugihara and Enomoto, 2017), (Peña-Parás et al.,
and Kalaichelvan, 2017), (Xing et al., 2016), (Stoeterau 2020), (Yang et al., 2020)
et al., 2016), (Rathod et al., 2016), (Kawasegi et al., 2019), Grinding (Pratap et al., 2019), (Pratap and Patra, 2020), (Fang et al.,
(Dheeraj et al., 2020a), (Ghosh and Pacella, 2020), (Zhu 2017a), (Fang and Klein, 2019), (Klein et al., 2017), (Zhao et al.,
et al., 2016) 2020), (Wu et al., 2020), (Pratap and Patra, 2020), (Fang et al.,
Ceramic (Liu et al., 2018b), (Liu et al., 2018a), (Liu et al., 2017), ( 2016), (Fang et al., 2017b)
Pratap et al., 2019), (Pratap and Patra, 2020; Wu et al., Drilling (S, N. and G.L, S., 2018), (Niketh and Samuel, 2017), (Dheeraj
2020), (Pratap and Patra, 2020), (Wu et al., 2020) et al., 2020a)
Inconel 718 (Sugihara et al., 2017a), (Fang and Obikawa, 2017), ( Precision (Kawasegi et al., 2017), (Kawasegi et al., 2019), (Zhang et al.,
Alagan et al., 2019), (Sivaiah et al., 2020) Machining 2019a)
Stainless Steel (Ahmed et al., 2020), (Liu et al., 2019a), (Vasumathy and
Meena, 2017)
Composites (Chen et al., 2019a), (Arulkirubakaran et al., 2019)
Others (Dinesh et al., 2016), (Fang et al., 2017a), (Fang and Klein,
2019)

Fig. 18. Machining processes used to test the surface texturing effects.

appears to be perennial.
The noticeable dearth of published articles is even more crucial for
studies covering the effect of textured tools on the chip formation and its
controlling techniques, which affect all the other output parameters in
machining. Despite the existence of recent trend regarding the appli­
cation of surface textures in grinding and drilling process, less than one
tenth of the total research record the same. In this series, milling and
precision machining have been recorded by even a lesser number of
researchers, consisting of surface textures. Due to this scenario, the Fig. 19. Texture production process/methods.
authors would like to strongly encourage the researchers to investigate
the effects of tool surface texturing in other such machining processes the surface patterns. The greater use of laser manufacturing in tool
also, where much research is required. texturing is understandable since the laser ablation process is relatively
Fig. 19 summarizes the surface texturing methods used to engineer well established and can easily be applied to the surface of cutting tools,
the tools’ surface, with the corresponding papers listed in Table 3. and it provides high accuracy and reproducibility. Electrical discharge
Almost two-third of the papers reviewed used laser texturing to fabricate

16
A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Table 3 Table 4
Discretization of the texture production methods. Discretization of the tool materials.
Laser (Zhou et al., 2019), (Singh et al., 2019), (Mishra et al., 2019), (Li et al., Uncoated Wc- (Zhou et al., 2019), (Singh et al., 2019), (Patel et al., 2019), (
2019), (Ge et al., 2019), (Chen et al., 2019a), (Yang et al., 2018), (Xing Co Palanisamy et al., 2019), (Lian et al., 2019), (Ge et al., 2019), (
et al., 2018), (Su et al., 2018), (S, N. and G.L, S., 2018), (Pang et al., 2018), ( Dhage et al., 2019), (Chen et al., 2019a), (Arulkirubakaran et al.,
Pan et al., 2018), (Orra and Choudhury, 2018), (Mishra et al., 2018b), ( 2019), (Yang et al., 2018), (S, N. and G.L, S., 2018), (Pang et al.,
Mishra et al., 2018a), (Liu et al., 2018b), (Liu et al., 2018a), (Lian et al., 2018), (Mishra et al., 2018a), (Liu et al., 2018b), (Liu et al., 2018a),
2018), (Li et al., 2018), (Kang et al., 2018b), (Kang et al., 2018a), (Hao (Lian et al., 2018), (Li et al., 2018), (Kang et al., 2018b), (Gajrani
et al., 2018), (Durairaj et al., 2018), (Cui et al., 2018), (Zhang et al., 2017), et al., 2018b), (Durairaj et al., 2018), (Arulkirubakaran et al.,
(Vasumathy and Meena, 2017), (Sugihara et al., 2017b), (Sugihara et al., 2018), (Vasumathy and Meena, 2017), (Sugihara et al., 2017b), (
2017a), (Sugihara and Enomoto, 2017), (Su et al., 2017), (Sasi et al., 2017), Sugihara and Enomoto, 2017), (Song et al., 2017), (Niketh and
(Niketh and Samuel, 2017), (Liu et al., 2017), (Li et al., 2017), (Fang and Samuel, 2017), (Liu et al., 2017), (Li et al., 2017), (Duan et al.,
Obikawa, 2017), (Duan et al., 2017b), (Duan et al., 2017a), (Chen et al., 2017b), (Duan et al., 2017a), (Chen et al., 2017), (Xing et al.,
2017), (Xing et al., 2016), (Sun et al., 2016), (Stoeterau et al., 2016), ( 2016), (Sun et al., 2016), (Stoeterau et al., 2016), (Arulkirubakaran
Sharma and Pandey, 2016a), (Dinesh et al., 2016), (Liu et al., 2019b), ( et al., 2016), (Sharma and Pandey, 2016a), (Rathod et al., 2016), (
Alagan et al., 2019), (Duan et al., 2019), (Grguraš and Pušavec, 2019), ( Kim et al., 2016), (Dinesh et al., 2016), (Alagan et al., 2019), (Duan
Ahmed et al., 2020), (Peña-Parás et al., 2020), (Mishra et al., 2020), ( et al., 2019), (Grguraš and Pušavec, 2019), (Ahmed et al., 2020), (
Vignesh et al., 2020), (Dheeraj et al., 2020a), (Ghosh and Pacella, 2020), ( Mishra et al., 2020), (Dheeraj et al., 2020a), (Patel et al., 2020), (
Sivaiah and Bodicherla, 2020), (Yang et al., 2020), (Sivaiah et al., 2020), ( Sivaiah and Bodicherla, 2020), (Yang et al., 2020), (Singh et al.,
Singh et al., 2020), (Klein et al., 2017), (Fang and Klein, 2019), (Fang et al., 2020), (Qi et al., 2020), (Zhu et al., 2016), (Klein et al., 2017), (
2017a), (Zhao et al., 2020), (Fang et al., 2016), (Fang et al., 2017b) Fang et al., 2017a), (Fang et al., 2016), (Fang et al., 2017b)
EDM (Patel et al., 2019), (Palanisamy et al., 2019), (Liu et al., 2019a), (Gajrani Coated (Mishra et al., 2019), (Liu et al., 2019a), (Rajbongshi et al., 2018), (
et al., 2019), (Arulkirubakaran et al., 2019), (Rajbongshi et al., 2018), ( Wc-Co Mishra et al., 2018b), (Arumugaprabu et al., 2018), (Zhang et al.,
Kumar and Patel, 2018), (Arulkirubakaran et al., 2018), (Song et al., 2017), 2017), (Fang and Obikawa, 2017), (Liu et al., 2019b), (Rajbongshi
(Arulkirubakaran et al., 2016), (Kim et al., 2016), (Pratap et al., 2019), ( and Sarma, 2019), (Peña-Parás et al., 2020), (Sarma and
Rajbongshi and Sarma, 2019), (Sarma and Rajbongshi, 2020), (Patel et al., Rajbongshi, 2020), (Vignesh et al., 2020), (Sivaiah et al., 2020)
2020), (Qi et al., 2020), (Pratap and Patra, 2020), (Pratap and Patra, 2020), Diamond / (Su et al., 2018), (Hao et al., 2018), (Su et al., 2017), (Kawasegi
(Wu et al., 2020) PCD et al., 2017), (Pratap et al., 2019), (Kawasegi et al., 2019), (Ghosh
Others (Lian et al., 2019), (Feng et al., 2019), (Dhage et al., 2019), (Sawant et al., and Pacella, 2020), (Pratap and Patra, 2020), (Fang and Klein,
2018), (Gajrani et al., 2018b), (Gajrani et al., 2018a), (Arumugaprabu 2019), (Zhang et al., 2019a), (Wu et al., 2020), (Pratap and Patra,
et al., 2018), (Wei et al., 2017), (Kawasegi et al., 2017), (Jesudass Thomas 2020)
and Kalaichelvan, 2017), (Feng et al., 2017), (Rathod et al., 2016), ( Ceramic (Feng et al., 2019), (Xing et al., 2018), (Orra and Choudhury,
Kawasegi et al., 2019), (Zhang et al., 2019a), (Zhu et al., 2016) 2018), (Kumar and Patel, 2018), (Cui et al., 2018), (Wei et al.,
2017), (Feng et al., 2017)
HSS (Gajrani et al., 2019), (Sawant et al., 2018), (Kang et al., 2018a), (
machining (EDM) is a recent trend, as it is even cheaper than laser Gajrani et al., 2018a), (Sasi et al., 2017), (Jesudass Thomas and
Kalaichelvan, 2017)
texturing. However, this technology allows only those textures that are
CBN / pCBN (Li et al., 2019), (Pan et al., 2018), (Sugihara et al., 2017a), (Zhao
considerably larger than the ones manufactured by laser texturing. Such et al., 2020)
a limitation presents an unavoidable drawback of EDM, which goes
against manufacturing the smallest possible textures, even at a nano­
scale. Although laser texturing fulfills all the current requirements for
texture production in terms of precision and accuracy. Hence, the au­
thors would like to recommend the researchers to investigate some
potential alternatives for large-scale production.
Fig. 20 summarizes the tool materials used for examining the surface
textures, reviewed in the present paper. The corresponding papers are
listed in Table 4. Almost 60 % of the textured materials are uncoated
cemented carbide. The fact that cemented carbide tools dominate the
tooling market (García et al., 2019) combines with the already estab­
lished knowledge of this material ablation’s behavior under laser Fig. 21. Location on the tool where the texture was placed in the arti­
machining. One of the main gaps of knowledge in this field is investi­ cles reviewed.
gating the effects of surface texturing on coated tools. The reason is that
the process is not expected to weaken the coating adhesion in the sub­ studies. According to most of the authors, the texture choice the rake
strate or its integrity near the texture edges. The surface texturing of surface is not only because it is generally easier to fabricate the textures
ultra-hard materials is also a challenge since the literature is still scarce there, but also is the region with more tribological interaction with the
regarding the ablation of those materials and the tool’s embrittlement chip. As reported by Durairaj et al. (2018), most of the authors found
near the cutting edges. Research on textured tools of ceraamic, pCBN or that textures on the rake face decreased the contact area in the chip-tool
PCD is scarce and appears as a future trend. interface, leading to lower cutting forces, friction coefficient, and
Fig. 21 summarizes the surfaces chosen to fabricate the surface tex­ machining temperatures. The greatest barrier to the investigation of
tures in the reviewed papers. The corresponding papers are listed in textures in other regions of the tool is because the laser machining is still
Table 5. The rake face corresponds to the overwhelming majority of the the main method of texture manufacturing (as shown in Fig. 19).
Despite the accuracy and reproducibility of this technique, the dif­
ficulty in focusing the laser beam on regions with significant changes in
the topography such as chip-breakers or curved surfaces (as in integral
drills and mills), explains why this process is overwhelmingly more
investigated in the rake face of plain cemented carbide inserts. Thus,
more flexible technologies of producing the textures are highly desir­
able, so that this technique can not only be applied for texturing other
regions of the tools but can also gain greater industrial competitiveness.
Regarding the textures’ location in relation to the cutting edges, their
positioning was proven to be the most important geometric parameter.
Fig. 20. Tool materials reviewed in the present work.

17
A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

Table 5 Table 6
Discretization of the location of the texture. Discretization of the texture geometries.
Rake (Zhou et al., 2019), (Patel et al., 2019), (Palanisamy et al., 2019), ( Linear Groove (Zhou et al., 2019), (Patel et al., 2019), (Palanisamy et al., 2019), (
Face Mishra et al., 2019), (Liu et al., 2019a), (Lian et al., 2019), (Li et al., Liu et al., 2019a), (Lian et al., 2019), (Ge et al., 2019), (Gajrani
2019), (Ge et al., 2019), (Gajrani et al., 2019), (Feng et al., 2019), ( et al., 2019), (Feng et al., 2019), (Dhage et al., 2019), (Chen et al.,
Dhage et al., 2019), (Chen et al., 2019a), (Arulkirubakaran et al., 2019), 2019a), (Su et al., 2018), (Rajbongshi et al., 2018), (Pang et al.,
(Yang et al., 2018), (Xing et al., 2018), (Su et al., 2018), (Sawant et al., 2018), (Liu et al., 2018b), (Kumar and Patel, 2018), (Gajrani et al.,
2018), (Pang et al., 2018), (Pan et al., 2018), (Orra and Choudhury, 2018a), (Arumugaprabu et al., 2018), (Vasumathy and Meena,
2018), (Mishra et al., 2018b), (Mishra et al., 2018a), (Li et al., 2018), ( 2017), (Sugihara et al., 2017a), (Su et al., 2017), (Liu et al., 2017),
Kumar and Patel, 2018), (Kang et al., 2018b), (Kang et al., 2018a), (Hao (Kawasegi et al., 2017), (Feng et al., 2017), (Duan et al., 2017b), (
et al., 2018), (Gajrani et al., 2018b), (Gajrani et al., 2018a), (Durairaj Duan et al., 2017a), (Chen et al., 2017), (Kim et al., 2016), (Dinesh
et al., 2018), (Cui et al., 2018), (Arulkirubakaran et al., 2018), (Zhang et al., 2016), (Liu et al., 2019b), (Kawasegi et al., 2019), (Duan
et al., 2017), (Wei et al., 2017), (Vasumathy and Meena, 2017), ( et al., 2019), (Ghosh and Pacella, 2020), (Patel et al., 2020), (
Sugihara et al., 2017b), (Sugihara and Enomoto, 2017), (Su et al., 2017), Sivaiah and Bodicherla, 2020), (Pratap and Patra, 2020), (Zhu
(Song et al., 2017), (Sasi et al., 2017), (Li et al., 2017), (Kawasegi et al., et al., 2016), (Pratap and Patra, 2020), (Fang et al., 2016), (Fang
2017), (Jesudass Thomas and Kalaichelvan, 2017), (Feng et al., 2017), ( et al., 2017b)
Duan et al., 2017b), (Duan et al., 2017a), (Chen et al., 2017), (Xing et al., Dimple (Singh et al., 2019), (Li et al., 2019), (Yang et al., 2018), (Sawant
2016), (Sun et al., 2016), (Stoeterau et al., 2016), (Arulkirubakaran et al., 2018), (S, N. and G.L, S., 2018), (Mishra et al., 2018a), (Li
et al., 2016), (Sharma and Pandey, 2016a), (Rathod et al., 2016), (Kim et al., 2018), (Durairaj et al., 2018), (Sugihara et al., 2017b), (
et al., 2016), (Dinesh et al., 2016), (Liu et al., 2019b), (Pratap et al., Sugihara and Enomoto, 2017), (Song et al., 2017), (Sasi et al.,
2019), (Kawasegi et al., 2019), (Duan et al., 2019), (Grguraš and 2017), (Niketh and Samuel, 2017), (Jesudass Thomas and
Pušavec, 2019), (Ahmed et al., 2020), (Peña-Parás et al., 2020), (Mishra Kalaichelvan, 2017), (Stoeterau et al., 2016), (Sharma and Pandey,
et al., 2020), (Vignesh et al., 2020), (Ghosh and Pacella, 2020), (Patel 2016a), (Alagan et al., 2019), (Vignesh et al., 2020), (Dheeraj
et al., 2020), (Sivaiah and Bodicherla, 2020), (Yang et al., 2020), ( et al., 2020a), (Yang et al., 2020), (Singh et al., 2020), (Klein et al.,
Sivaiah et al., 2020), (Singh et al., 2020), (Qi et al., 2020), (Pratap and 2017), (Fang et al., 2017a), (Zhang et al., 2019a)
Patra, 2020), (Klein et al., 2017), (Fang and Klein, 2019), (Fang et al., Pattern (Mishra et al., 2019), (Arulkirubakaran et al., 2019), (Orra and
2017a), (Zhang et al., 2019a), (Zhu et al., 2016), (Pratap and Patra, Groove Choudhury, 2018), (Mishra et al., 2018b), (Cui et al., 2018), (
2020), (Zhao et al., 2020), (Wu et al., 2020) Arulkirubakaran et al., 2018), (Sun et al., 2016), (Arulkirubakaran
Flank (Rajbongshi et al., 2018), (Liu et al., 2018b), (Liu et al., 2018a), ( et al., 2016), (Rathod et al., 2016), (Pratap et al., 2019), (Grguraš
Face Arumugaprabu et al., 2018), (Sugihara et al., 2017a), (Liu et al., 2017), ( and Pušavec, 2019), (Ahmed et al., 2020), (Sivaiah et al., 2020), (
Fang and Obikawa, 2017), (Rajbongshi and Sarma, 2019), (Sarma and Zhao et al., 2020), (Fang et al., 2016), (Fang et al., 2017b)
Rajbongshi, 2020) Miscellaneous (Pan et al., 2018), (Kang et al., 2018b), (Kang et al., 2018a), (
Both (Singh et al., 2019), (S, N. and G.L, S., 2018), (Lian et al., 2018), (Niketh Gajrani et al., 2018b), (Wei et al., 2017), (Li et al., 2017), (Fang
and Samuel, 2017), (Alagan et al., 2019), (Dheeraj et al., 2020a) and Obikawa, 2017), (Xing et al., 2016), (Rajbongshi and Sarma,
2019), (Peña-Parás et al., 2020), (Mishra et al., 2020), (Sarma and
Rajbongshi, 2020), (Qi et al., 2020), (Fang and Klein, 2019), (Wu
In general, the related studies showed a direct relationship among the et al., 2020)
Nano (Xing et al., 2018), (Liu et al., 2018a), (Lian et al., 2018), (Hao
proximity of the textures pertaining to the cutting edge, its efficiency in
et al., 2018), (Zhang et al., 2017)
reducing wear, forces, and cutting temperatures. However, there is still a
huge scarcity of the adequate data and publications in alliance to the
tangible effects of texture positioning in the machinability of a system. perpendicular to the chip flow are better since they restrain the chip flow
For example, Ling et al. (2013) showed that texturing the margin area of and reduce its curling radius. However, as pointed by Su et al. (2018),
drill bits reduced the wear significantly, showing the potential of some authors claim that grooves parallel to the chip flow are better, as
texturing other areas rather than the rake face solely, even for the more this configuration facilitates the chip flow. Some authors even claim that
complex cutting tool geometry of the drill bits. the groove direction is an irrelevant variable (Kang et al., 2018a). For
Regardless the position where the textures were applied, the depth future studies, a deeper evaluation of the groove direction in the tribo­
proved to be a parameter of little relevance, as long as the textures are system of chip-tool interface, is highly recommended. It is also suggested
not too shallow to be quickly consumed by wear or too deep to to conduct more numbers of studies on the effects of other surface
compromise with the tools’ surface integrity. The literature in general, texturing patterns rather than grooves and dimples.
recommends a ratio between 3 and 7 for the width / depth, since this According to most of the studies, generally texturing, even at the
range influences the lubrication of the cutting fluids and the chip flow nanoscale, leads to a reduction (up to 60 %) in the effects of adhesion.
the most. The reduction in material adhesion appears to be inversely proportional
Fig. 22 summarizes the surface texture geometries evaluated in the to the cutting speed with the positive effects, which is generally negli­
papers and reviewed here. The corresponding papers are listed in gible at lower cutting speeds. The dimple textures proved to be the most
Table 6. The groove textures are most commonly found in more than half efficient pattern in reducing material adhesion. This effect occurs mainly
of the studies, followed by dimple ones in almost a quarter of the papers. by reducing the workpiece-tool-chip contact areas, acting in the reduc­
The last quartile consists of chevron textures, nano-textures, and other tion of the mechanical interlock phenomenon.
geometries or combinations of geometries. Regarding the groove tex­ Tribologically, the best direction of groove textures is perpendicular
tures, besides geometric parameters, the texture orientation in relation to the chip flow (parallel to the main cutting edge), being more effective
to the chip flow direction is pointed as a crucial variable. As pointed by in roughing type of material removal. However, for finishing material
Arulkirubakaran et al. (2019), most authors concluded that grooves removal, the linear grooves are not relevant, with the probable expla­
nation of being the ones which allow a lesser flow of material over the
textures. In general, the grooved textures parallel to the main cutting
edge, also added an improvement in the access of lubricant at the cutting
interface, due to its additional advantages with flood, MQL or cryogenic
cooling systems concomitantly.
The frequency and degree of segmentation of the chip can have
significant reductions in the presence of textures. The textures in the
form of grooves presented the greatest influence in the chip formation
(mainly by the groove size), and when the groove is in the direction
parallel to the chip flow (perpendicular to the main cutting edge), the
Fig. 22. Texture geometries used in the papers reviewed in the present work.

18
A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

formation of the chip occurs more effectively. In general, textured tools Table 7
cause smoother chip formation when compared to non-textured tools. Discretization of the atmospheric conditions in the revised papers.
Dimple textures gave the best results in finishing operations, producing Dry (Patel et al., 2019), (Palanisamy et al., 2019), (Mishra
the smoother chips. et al., 2019), (Liu et al., 2019a), (Lian et al., 2019), (Li
The density of the textures is more influential than its geometry with et al., 2019), (Feng et al., 2019), (Dhage et al., 2019), (
Chen et al., 2019a), (Yang et al., 2018), (Xing et al., 2018),
respect to the reduction in cutting forces. This parameter is correlated
(Sawant et al., 2018), (Rajbongshi et al., 2018), (Pan et al.,
with the reduction of chip-tool contact area, where the denser (close to 2018), (Mishra et al., 2018b), (Mishra et al., 2018a), (Liu
each other) the textures, the lesser is the contact. However, if the tex­ et al., 2018b), (Liu et al., 2018a), (Li et al., 2018), (Kumar
tures’ width is too large, there may be chip stickiness on the textures. and Patel, 2018), (Kang et al., 2018a), (Gajrani et al.,
In the case of dimple-type textures, the parameter that most impacts 2018b), (Gajrani et al., 2018a), (Cui et al., 2018), (
Vasumathy and Meena, 2017), (Sugihara et al., 2017b), (Su
the cutting forces, roughness, and reduction of adhesion effects, is the
et al., 2017), (Sasi et al., 2017), (Niketh and Samuel, 2017),
size of textures. But for tool wear, the most influential parameter is the (Liu et al., 2017), (Li et al., 2017), (Jesudass Thomas and
distance between the textures and the cutting edge. For extremely high Kalaichelvan, 2017), (Duan et al., 2017b), (Duan et al.,
cutting speeds, dimple textures only work if the texture density is also 2017a), (Chen et al., 2017), (Xing et al., 2016), (Kim et al.,
2016), (Dinesh et al., 2016), (Pratap et al., 2019), (Duan
high. The textures’ size is more influential on dimple textures than
et al., 2019), (Rajbongshi and Sarma, 2019), (Sarma and
grooved textures when it comes to temperature-reduction effects. Rajbongshi, 2020), (Ghosh and Pacella, 2020), (Patel et al.,
The atmospheric condition’s influence is a variable of utmost 2020), (Yang et al., 2020), (Zhao et al., 2020), (Wu et al.,
importance since the claim for texturing the tool surfaces is to improve 2020)
the lubrication of the tribosystem. Fig. 23 summarizes the atmospheric Flood (Ge et al., 2019), (Pang et al., 2018), (Kang et al., 2018b), (
Durairaj et al., 2018), (Arumugaprabu et al., 2018), (Wei
condition used for analyzing the effect of tool surface texturing in the
et al., 2017), (Sugihara et al., 2017a), (Sugihara and
machinability. The corresponding papers are listed in Table 7. Almost Enomoto, 2017), (Fang and Obikawa, 2017), (Stoeterau
three-quarters of the papers investigated the surface texturing effects et al., 2016), (Liu et al., 2019b), (Kawasegi et al., 2019), (
under dry or flood conditions, which is understandable since those Alagan et al., 2019), (Grguraš and Pušavec, 2019), (Ahmed
et al., 2020), (Peña-Parás et al., 2020), (Qi et al., 2020), (
cutting atmospheres are more common in machining.
Zhu et al., 2016), (Zhang et al., 2019a), (Fang et al.,
The increasing pressure to move towards greener manufacturing 2017a), (Fang and Klein, 2019), (Klein et al., 2017), (Fang
made the self-lubricating coatings a trend, with more than one-tenth of et al., 2016), (Fang et al., 2017b)
the papers researching this technique. Although the MQL is also labeled Soft Coating / Self (Gajrani et al., 2019), (Arulkirubakaran et al., 2019), (Orra
as a greener alternative to flood lubrication, yet the studies involving Lubricating and Choudhury, 2018), (Lian et al., 2018), (Zhang et al.,
2017), (Song et al., 2017), (Kawasegi et al., 2017), (Feng
this technique represent only around one-tenth of the papers. The MQL
et al., 2017), (Sun et al., 2016), (Sharma and Pandey,
(or spraying) technique generally presented superior results in relation 2016a), (Rathod et al., 2016), (Vignesh et al., 2020), (
to the flood lubrication. According to the authors, the same reason lies in Dheeraj et al., 2020a)
the higher delivery pressure combined with the textures generating a MQL (Zhou et al., 2019), (Singh et al., 2019), (Su et al., 2018), (
S, N. and G.L, S., 2018), (Hao et al., 2018), (Kumar Mishra
thicker lubricating layer in the vicinity of the cutting interface. Because
et al., 2020), (Sivaiah and Bodicherla, 2020), (Sivaiah
of MQL technique’s potential, further research with varying the pa­ et al., 2020), (Singh et al., 2020), (Pratap and Patra, 2020),
rameters of the spray system using different types of textured tools is (Pratap and Patra, 2020)
highly encouraged. Investigations regarding the combination of cryo­ Others (Arulkirubakaran et al., 2018), (Arulkirubakaran et al.,
genic and high-pressure lubrication were almost absent. The probable 2016)

explanation of the same lies in the higher difficulties and costs of

implementing those techniques. grooves or other more complex patterns) showed better results
The textures can trap particles/debris originated in the cutting pro­ regarding this effect.
cess. For groove textures, the direction perpendicular to the chip flow is
the one with the most retention capacity. For dimples, this effect is 9. Future trends
directly proportional to the size of the texture since they have smaller
dimensions than most debris. However, the nano textures did not show Due to the development of materials that are increasingly difficult to
this effect on a significant scale. machine, there is a constant need to develop increasingly cost-effective
Textures have been increasingly used as reservoirs of solid lubri­ tools, leading to changes in the material and geometry of the cutting
cants, particularly with molybdenum disulfide (MoS2). The lubricant tools and their surface. The superficial texturing of the tools is presented
mechanism action occurs because tool worn particles, which are denser as one of the most promising development fronts for improving the
and harder than the work material, penetrate the textures through high cutting tools’ tribological performance.
cutting pressures, causing solid lubricant to overflow towards the cut­ The understanding of how textures affect variables such as
ting interface. In nano-scale textures, solid lubricants’ action is different machining forces and temperature, tool life, and surface finish, is
as there is no significant entrapment of particles. The textures filled with paramount, however, the understanding of the actual mechanism is still
solid lubricants act as sliding bearings. Due to the chaotic movement of a knowledge gap. This is in part due to the complexity of the cutting
material at the cutting interface, mixed textures (involving dimples, interface, caused independently by the wide range of tribological pairs
of tools, workpieces, and varieties of the lubricating and coolant media,
as well as their combined effect along with high pressure characteristics
during the shearing of the materials. According to the literature survey
conducted in this review, some of the key-points pertaining to the
application of textured tools in machining, are still dubious and there­
fore, need to be raised and addressed. Hence, the following research
topics are recommended:

• Mostly articles only indicate an increase in tool life on the basis of

reductions in cutting forces and temperatures. Probably the major
Fig. 23. Atmospheric conditions of the machining tests covered in the pre­ reasons for the lack of deep studies on the tool life are some of the
sent paper.

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A.R. Machado et al. Journal of Materials Processing Tech. 293 (2021) 117096

challenging analyses which include monitoring of classic parameters difficulties in producing the textures on tools with CB, moreover, in
such as flank, crater, or notch wear, wear mechanism analysis the orthogonal cutting process due to the ease of monitoring. Thus,
involving the textures themselves, and evaluation of critical analyses the studies on the effect of textures on tools of more complex ge­
associated with derivative cut in the edges of textures. ometries including their interaction with chip-breakers, are also
• Mostly studies in the literature have reported the influence of tex­ essential. It is also suggested to use techniques which can allow a
tures on cutting tools when machining carbon steels, titanium, and better assessment of the effects of textures on the thermal behavior of
aluminum alloys. Therefore, this work encourages further research cutting interface, such as the use of tool-workpiece thermocouple
on the effects of surface texturing of tools applied to machining Ni- measuring system. The understanding of material flow in textured
based superalloys, stainless steels, ceramic, and composite mate­ tools should also be looked over using special methods, such as
rials. These materials have high aggregated value and if the im­ quick-stop device and high-speed cameras. Pieces of information
provements from texturing are confirmed, then the application of derived from such experiments will lead to a better modeling of the
textures can be boosted for large-scale industrial applications. textures’ effect. This will further allow a greater accuracy in simu­
• The turning process corresponds to almost all the research associated lations, especially those implemented using the finite element
with textured cutting tools. The possible cause is the availability of method.
facilities for texturing turning tools as well as assessing forces and • With respect to the practical aspects, in all the research works, the
cutting temperatures in this process. However, texture presents texturing parameters were chosen on a random basis. For example,
much broader potentials, making it necessary to focus on research on the parameters such as: width, depth, and orientation are defined
other machining processes. more on the grounds of production capabilities of the texturing
• The advantages of using lasers to texturize cutting tools include the equipment rather than focusing on its effects. It would be essential to
versatility, precision reproducibility, and range of materials which define a method of modeling the effects of the dimension, orienta­
can be textured. However, laser machines are expensive and have tion, and shape of the texture more precisely for a certain machining
relatively low productivity for a large-scale production of textured condition. This way it can be made possible to optimize these pat­
tools. Therefore, it is recommended to investigate faster and more terns without any random investigation.
cost-effective methods for mass production of textured tools.
• Carbide tools dominate the cutting tool market, and therefore, there 10. Dedication
is a greater opportunity of texturing this material, especially using
laser ablation. The surface texturing of ultra-hard materials such as This paper is dedicated to the memories of two of the authors, Prof.
ceramic, PCBN, and PCD remains as a challenge, as evidenced by the Wisley Falco Sales and Prof. Emmanuel Okechukwu Ezugwu. Prof. Sales
still scarce literature covering the surface texturing methods for these was sadly defeated by the COVID19 virus, dying on 15th of June 2020,
materials. The primary reason of the same is the possibility of one week after the first submission of this paper. Prof. Sales was a
embrittlement of the tool close to the cutting edges resulting from the talented researcher with many contributions in the field of machining
texturing process. The need of exploring the production of textures in and tribology and has idealized the publication of this article. Prof.
these materials is largely important because the high hardness of Ezugwu died on 17th of September 2020. He was the Provost of the Air
such cutting tools can enhance the duration of texturing process and, Force Institute of Technology of Nigeria (AFIT), in the city of Kaduna,
consequently, their benefitting effects. Nigeria and his uncountable contributions in the field of metal cutting,
• Another chief knowledge gap in the tool texturing field is the principally in the machining of superalloys, have guaranteed a step
investigation of producing textures on the coated cutting tools. The ahead in the knowledge of this fantastic research area. With no doubt the
main disadvantage lies in the fact that it is necessary to have a very whole machining community will miss both the researchers. Before
precise control on the texturing method so that it does not reach the departing from this world, Prof. Ezugwu have put his fingers in this
substrate, otherwise stress concentration points may arise, which can paper without knowing that it would be the last. God bless the souls of
initiate and propagate cracks followed by reduction in tool life. these two fantastic colleagues.
• Additionally, there is a huge scope of studying the influence of tex­
tures of more complex patterns. These textures can be more effective
in retaining cutting fluids and reducing the workpiece-tool-chip Declaration of Competing Interest
contact areas. This can further lead to lower cutting forces and
machining temperatures, and consequently, increasing tool life. Even The authors declare that they have no known competing financial
the most researched patterns (groove and dimple) have not been interests or personal relationships that could have appeared to influence
investigated enough for clearly defining the most effective increase the work reported in this paper.
in the tool life.
• Understanding the effect of textures on other tool regions (apart from Acknowledgments
the rake surface) is another area requiring further exploration. The
difficulties in texturing the regions such as the flank surface, the The authors are grateful to the Brazilian research agencies CNPq,
corner, or the chamfer, can better explain this knowledge gap. FAPEMIG and Coordenação de Aperfeiçoamento de Pessoal de Nível
However, the application of non-traditional techniques such as ion Superior - Brasil (CAPES) - Finance Code 001 for financial support.
beam machining - IBM or micro-EDM, can be some of the possible
solutions to this problem. References
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