1. Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
McMaster University Canada
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Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
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2. Lubrication in cutting
lubricant
Infiltration of lubricant is controlled by capillary action and chip velocity-induced shear flow
Retention of the lubricant in the interface is as critical as its ingress
Lubrication may be enhanced through texturing the tool rake face surface
sticking
sliding
tool
chip
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
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Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
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Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

3. Femtosecond laser texturing
Enomoto & Sugihara (2010)
Texture is to be preferably oriented normal to the chip flow direction
Kawasegi et al (2009)
micro
nano
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
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Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

4. Electrochemical texturing
anode (workpiece)
metal layer
(cathode)
insulation layer
Zhu et al (2009)
dimpled texture
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
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*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

5. Electrical discharge texturing
Surfaces generated in electrical discharge machining (EDM) are isotropic and entail a positive skewness, which predisposes them towards effectively entraining lubricant
surface height
frequency
+ve skew
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

6. Objective of this work
To prove the concept of ED-textured cutting tools
Identify the envelope of EDM and cutting parameters in which such textures are effective
areal texture machined
with a block electrode
cutting edge
linear texture machined
with shim stock tooling
rake face
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

7. Experimental - EDM
copper electrodes with positive polarity
oil based dielectric
average gap voltage 100 V; duty factor 50%
Pulse current <72 A; pulse on-time <133 µs
Pulse current and on-time were varied to alter the geometry of the characteristic crater
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

8. Experimental - Cutting
In comparison to surface roughness and tool life, machining force is a better indicator of lubrication effectiveness, in terms of repeatability and resolution
De Chiffre & Belluco (2000)
tool
chip Fc Ff
friction angle
continuous & intermittent orthogonal cutting
AISI T-15 High Speed Steel ground inserts
SPG 432 geometry with 0° rake angle
annealed 1045 steel & 6061 Al workpieces
cutting speed 2−75 m/min; feed 0.025−0.1 mm
cutting width 3 mm; oil lubricant
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

9. Texture parameters
Texture depth was limited to prevent the tool from functioning as a restricted rake tool
relief on the
rake face to
restrict tool chip contact
restricted rake tool d e
Distance de is to be optimized with respect to the uncut chip thickness
Maximum force reduction referred to the texture with a roughness of 12 µm Ra, generated at a current of 39 A and an on-time of 42 µs
Texturing time is ~10 seconds
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

10. Effectiveness of ED-texture
lubricant application 30 60 90
120
150
180 16 20 24 28 32
Time (s)
ground tool
Friction angle (°) 30 60 90
120
150
180 16 20 24 28 32
Friction angle (°)
Time (s)
textured tool
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

11. Force reduction in continuous cutting
Texturing decreases the forces and the variability, with the effect more pronounced in the feed direction
1.5
3.0
4.5
6.0
Feed force (x102 N)
non-textured
textured 2 4 6 8 10 12
Cutting force (x102 N)
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

12. Force reduction in intermittent cutting1 2 3 4 5 6
Feed force (x102 N)
Time (s) 8 10 12
Cutting force (x102 N)
textured
non-textured
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
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*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Feed force reduction is higher in intermittent cutting as the lubricant is directly replenished on the tool rake face during the non-cutting interval
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

13. Effect of cutting parameters on force reduction
Cutting speed (m/min)
50 µm 15 30 45 60 75 90 5 10 20 25
% reduction in feed force
25 µm feed 5 10 15 20 25 30 40 50
Cutting speed (m/min)
continuous
intermittent
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Texturing is more effective at the low end of typical cutting speeds, at fine feeds and in intermittent cutting
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

14. Force reduction in cutting of aluminum5 10 15 20 25
0.0
0.5
1.0
1.5
2.0
2.5
Feed force (x102 N)
Time (s) 1 2 3 4
Cutting force (x102 N)
non-textured
textured
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Forces and the associated variability were significantly lower as the lubricant used was specifically formulated for cutting aluminum
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

15. Effect of texture locationd e
tool
chip h 3 6 9 12 15 18 20 22 24 26
Friction angle (°)
(de/h)
h = 25 µm
100 µm
50 µm
Force reduction is maximized when (de/h) is ~2−3
As the tool chip contact length is typically 4−6 times the feed h, this implies that texturing needs to correspond to just the sliding region
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

16. Comparison of linear and areal textures20 40 60 80
100 5 10 15 25 30
% reduction in force
% area textured
feed force
cutting force
areal
linear
Textured area was varied by altering the pitch in the linear texture
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Results confirm that the areal texture is to be preferred over a linear one
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

17. Role of texture parameters on force reduction
Skewness
0.0
0.2
0.4
0.6 5 10 15 20 25 30 35
% reduction in force
feed force
cutting force
1.5
2.0
2.5
3.0
3.5
4.0 5 10 15 20 25 30 35
Kurtosis
Force reduction showed no systematic trends with respect to either the Ra roughness or the pulse parameters
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Force reduction exhibited defined maxima with respect to skewness and kurtosis of the texture
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

18. Conclusions
Electrical discharge texturing has been demonstrated to bring about a significant (15−40%) reduction in machining force through enhanced lubrication at the tool-chip interface
The skewness and kurtosis of the texture are good indicators of the extent of force reduction
The concept is attractive for application in broaches, taps, gear cutting tools and possibly forming tools
Mechanical imprinting of said texture during the compaction phase of tool inserts (as opposed to EDM of inserts) may be explored
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.
Performance of electrical discharge textured cutting tools
P. Koshy, J. Tovey
61st CIRP General Assembly
Budapest, August 24, 2011

19. for your kind attention!
Canadian Network of Centers of Excellence
Natural Sciences & Engineering Research Council of Canada
Thank you
for your kind attention!
This file is a template for making effective slides for scientific presentations.* Although much about the layout and typography contrasts sharply with the defaults of PowerPoint, these changes are done so to make the slides more effective at communicating technical information. The design advocated by this template arises from pages of The Craft of Scientific Presentations (Springer, 2003). The homepage for this and other similar templates exist at the following web site:
Right now you are viewing the notes pages. To work on the slides, click on “Slide” under “View.”
Reference slide: Katrina Aspmo, Torunn Berg, and Grethe Wibetoe, “Atmospheric Mercury Depletion Events (AMDEs) in Polar Regions During Arctic Spring,” presentation (Oslo, Norway: University of Oslo, 16 June 2004).
___________________________________________
*You are more than welcome to use this template for your presentation slides. You may not, though, distribute this template for profit or distribute this template without giving credit to the source.