Analysis of Cutting Equation for Micro-Groove Tool and Its Impact on Shear Angle and Cutting Force in Tuning AISI201

The face of cutting tools serves as the critical interface for chip–tool interaction and wear initiation, significantly influencing tool performance and service life. By implementing micro-groove structures on the face to reduce the chip–tool contact area, the cutting mechanics of the tool are altered. Theoretical analysis indicates that the cutting equations of the grooved tool have changed, with the modified tool exhibiting a larger shear angle compared to the original design. Finite element simulations and experiments demonstrate that grooved tool exhibit optimized cutting mechanics, characterized by a larger shear angle and improved edge sharpness. The shear angle of grooved tool is increased by about 3 degrees and the chip thickness is reduced by about 0.05 mm. Cutting tests confirm that the grooved tool reduces the main cutting force by more than 18%, with a smaller wear area on the face and improved wear conditions near the cutting edge. Due to materials such as stainless steel and titanium alloy, which have similar difficult-to-machine properties. The present results are based on AISI 201 and the specific groove geometry used in this study, and further work is required before generalizing to other difficult-to-cut materials and groove designs. In summary, based on the experimental data, the micro-groove cutting tool outperforms the original tool in terms of shear angle, cutting force, and durability. Specifically, the shear angle of the micro-groove cutting tool is larger, the cutting force is reduced, and the wear on the face is decreased.