Research on milling performance of textured carbide milling cutter based on laser cladding principle

Abstract. Traditional laser processing of micro-textures directly impacts the work surface, leading to significant crack propagation and pore formation around textured pits. These defects result in poor surface quality and insufficient hardness, which in turn deteriorate the tool's milling performance and surface hardness. To enhance the surface properties of the texture and improve the milling performance of the ball-end milling cutter, this paper integrates the prefabricated powder-feeding laser cladding method with the laser preparation micro-texture technique to establish a modified textured ball-end milling cutter milling titanium alloy test platform. The milling performance of cemented carbide modified textured ball-end milling cutters, both with and without coating deposition treatment, was investigated. The findings indicate that at an average laser energy density of 70.8 W cm−2, the grain structure on the surface of the modified textured tool has a fine-grain-strengthening effect, enhancing surface hardness and reducing vibration. During milling, aluminum in the coating oxidizes to form an Al2O3 film with a high melting point and solid lubrication properties, effectively lowering the friction coefficient and improving cutting stability. The surface micro-hardness of the modified textured tool increases by approximately 35 %, accompanied by a substantial presence of hard phases within the strengthening layer. As wear progresses, the detachment of these hard phases further decreases the friction coefficient, resulting in an average reduction of frictional force by about 13.1 %. Concurrently, the lifespan of the strengthening layer is extended, which effectively mitigates wear on the rake face of the ball-end milling cutter. Concurrently, the passivation of the tool edge during the cutting process is mitigated, leading to reduced material adhesion phenomenon in the cutting process, which ultimately enhances the machined surface quality of the workpiece. Moreover,the deposition of the coating not only establishes a dense alumina structure that resists wear at the tool–chip interface but also enhances the bonding strength of the tool surface, curbing the formation of built-up edges and promoting better surface roughness in the machining of titanium alloys. Overall, this study achieves a synergistic enhancement of surface wear resistance and cutting performance in cemented carbide tools, providing valuable insights for the efficient machining of difficult-to-cut materials in aerospace and shipbuilding applications.