Abstract
The broaching process is a heavy-duty and highly efficient metal cutting technique. The heavy load encounters significant thermal and mechanical stresses on the tool during broaching, resulting in considerable friction within the tool-chip contact area. The friction adversely affects both workpiece quality and tool life. To address this issue, laser technology is utilized in this study to create three distinct textures on the rake face of the broach. Subsequently, an innovative rotary covering device is developed to cover a solid lubricant (copper) onto both surfaces and grooves of cutting tool. Broaching test is conducted to evaluate the impact of different textures and copper on chip morphology, including chip deformation and burr width. The findings demonstrate that employing a stripe-textured broach reduces the chip deformation coefficient by 16.1% compared to its non-textured counterpart. Furthermore, covering copper through rotational friction leads to an additional reduction of 7.7% in the chip deformation coefficient. Copper not only repairs surface defects but also forms a lubricating film during cutting operations, thereby serving as an effective solid lubricant. The synergistic interaction between texture and copper enhances heat dissipation during cutting processes, consequently reducing temperatures within the tool-chip contact area. The temperature reduction alleviates plastic deformation in localized regions of the workpiece, resulting in narrower burrs. Therefore, the use of rotary friction for covering copper onto the rake face of a broaching tool represents a straightforward yet cost-effective strategy for optimizing frictional conditions and enhancing the cutting performance.