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HomeDefect and Diffusion ForumDefect and Diffusion Forum Vol. 450The Role of Tool Texture Design on the Chip...

The Role of Tool Texture Design on the Chip Formation in PEEK Machining

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Abstract:

Biocompatible, chemical-resistant, and low-wear-rate materials are essential in biomedical applications to produce durable components that can withstand the conditions of the human body. PEEK is increasingly used due to its mechanical properties that are similar to those of human bones, making it a common material in orthopaedic prostheses. However, its low thermal conductivity, coupled with limited ductility, makes it difficult to machine. One of the main issues is the formation of continuous chips, which can reduce productivity and compromise final product quality. Innovative approaches, such as cryogenic machining and textured tools, have been recently studied to overcome this issue. Cryogenic machining can actively change the chip morphology from continuous, obtained in dry machining, to fragmented. On the other hand, textured tools can alter the chip flow, acting as chip breakers. This work examines how variations in texture design, specifically the distance of the texture from the cutting edge and the groove depth, may affect chip formation. To do that, turning trials were conducted under both dry and cryogenic cooling conditions using different textured tools. The results were assessed based on chip-tool contact length, chip dimensions, and morphology. Forces and temperatures were also acquired during the turning trials. The findings are that textured tools modify chip morphology in both dry and cryogenic conditions by altering chip flow on the insert. Deeper textures placed close to the cutting edge enhance chip breakability during cryogenic cooling and modify chip morphology in both machining environments.

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Periodical:

Defect and Diffusion Forum (Volume 450)

Pages:

9-18

DOI:

https://doi.org/10.4028/p-gXx7ph

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Online since:

April 2026

Authors:

Anna Bottin*, Rachele Bertolini, Haizea Gonzalez, Eneko Ukar, Stefania Bruschi

Keywords:

Chip Breakability, Polymer Turning, Textured Tools

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Creative Commons CC BY 4.0

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* - Corresponding Author

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