Minimum cutting thickness modeling and chip formation mechanism under the coupled effects of a quadratic parabolic cutting edge and composite micro-texturing

While tool edge geometries and micro-textures improve machining, their coupling effect at the minimum cutting thickness remains unclear.This study establishes a coupled model of a quadratic parabolic edge and composite micro-texture. Using simulations and orthogonal cutting experiments, we examined how edge parameter A and texture parameters ( l 2 , l 4 , r 1 ) influence minimum cutting thickness and chip morphology. A critical coefficient K divides the process into plowing, transition, and stable stages. Results show parameter A primarily dictates cutting forces and chip curl. The synergy between the edge and micro-texture ( r 1 = 80–100μm) transitions chip formation from extrusion to sliding, suppressing secondary cutting. An optimized strategy ( A = 10–25, l 4 = 10–15μm, r 1 = 80–100μm) is proposed to actively manage cutting forces and chip morphology.