Synergistic effects of bionic micro-texture and 3DG-ODA-SiO2 hybrid nanofluids on wear behavior of PCBN tools in MQL-assisted milling of H13 steel

To enhance the lubrication effect of the 3DG-ODA-SiO 2 hybrid nanofluid and mitigate chipping tendency and adhesive wear of PCBN tools during machining of difficult-to-cut materials, a novel hybrid bionic texture derived from dung beetles and shark skin was designed on the tool surface. The textures were fabricated and characterized, and nanofluid minimum quantity lubrication (NMQL)-assisted milling experiments on H13 steel were conducted using PCBN tools with different textures. The results showed that the contact angle of 3DG-ODA-SiO 2 nanofluid on microdimple-groove-textured (DST) tools was reduced by 40.66% compared with that on non-textured (NT) tools. Under 3DG-ODA-SiO 2 nanofluid conditions, compared to the non–textured (NT) tool, the DST tool exhibited reductions of 30.77% in cutting force and 37.78% in cutting temperature, along with markedly enhanced surface quality and tool life. Wear morphology analysis revealed that DST facilitates the formation of a stable and continuous oil film in the cutting zone through oil storage in microdimples and oil guidance in microgrooves. The 3DG-ODA-SiO 2 nanoparticles in the lubricating film can not only enhance the heat transfer capacity of the cutting zone but also form a “sandwich” anti-friction structure, which reduces friction and adhesive wear through the synergistic effects of rolling and sliding. Meanwhile, SiO 2 nanoparticles enhance the wear resistance of the textured surface by filling surface defects.