Production and characterization of texture in PCD cutting tools with femtosecond laser

Abstract

This study investigates the creation of textures on polycrystalline diamond (PCD) cutting tools using femtosecond laser processing and evaluates the influence of these textures on the turning of AA2011-T4 aluminum alloy. Four types of linear textures with varying orientations and dimensions were developed, and their quality was assessed through 3D profilometry and energy-dispersive spectroscopy (EDS). The turning tests evaluated the surface roughness of the machined workpiece, material adhesion on the tool, and the effect of incorporating solid lubricant microparticles (MoS₂) into the textures. The results indicate that femtosecond laser texturing was effective, causing no thermal damage or graphitization of the PCD. During machining, textures oriented perpendicular to the cutting edge reduced aluminum adhesion and lead to better surface finish. In contrast, textures parallel to the cutting edge intensified material anchoring, increasing the risk of tool structure failure. The use of MoS₂ decreased material retention within the textures, facilitated chip evacuation, and contributed to improved machining performance. The greatest reduction in roughness (49 %) was observed for larger perpendicular textures combined with MoS₂. Additionally, larger textures demonstrated superior performance by promoting chip segmentation and reducing thermal effects. The results demonstrate that femtosecond laser texturing is a viable technique for optimizing the performance of cutting tools in the turning of aluminum alloys, enhancing the surface quality of the machined part, and reducing tool wear.