Titanium alloy material has physical properties such as low thermal conductivity, high hardness, and surface resilience, which are prone to problems such as large milling force, low machining efficiency, and poor surface quality in processed products during dry milling. This document details our process of isolating micro-textures from biological structures, applying them to cutting tool surfaces to create micro-texture milling cutters, and employing this micro-texture technique to reduce friction and prevent wear on these cutters. According to the milling dosage and the installation position between the tool and the workpiece, the effective working area of the cutting edge of the ball-end milling cutter is calculated. At the same time, a self-lubricating cutter was constructed by using a laser to process micro-textures and filling solid lubricant inside the micro-textures. An analysis was conducted to compare the milling efficiency of bionic microtextured cutters in both dry and micro-lubricated environments. It was found that the self-lubricating tool promoted a 3% to 5% decrease in milling force, a reduction in the coefficient of friction, a high surface finish of the machined workpiece, and an alleviation of chip sticking at the edge area.

Dry cutting is an effective method to realize the concept of green cutting today. However, in the process of cutting bearing steel, the high temperatures and high pressures produced by the cutting tool and chip under dry friction seriously affect the machining performance of the tool. Therefore, a bionic microstructure tool based on bionics is proposed to improve the cutting performance and reduce friction by changing the size parameters of the microstructure. On the basis of finite element simulation and cutting tests, the cutting force, surface roughness, and chip shape are used to evaluate the cutting performance. It is found that composite bionic micro-textured tools have a significantly reduced cutting force compared with non-micro-textured tools; composite bionic micro-textured tools lead to a reduction in surface roughness of 10–25%; and composite bionic micro-textured tools are more prone to enhancing the curling and breaking of chips. In addition, with the increase in the microstructure area occupancy, the cutting performance of the tool was also significantly improved. Moreover, it was found that the cutting performance of the tool was improved when the area occupancy of the micro-texture on the front face of the tool was increased.

To address the common issues of high cutting forces, poor surface quality, and chip wrapping in aluminium alloy machining, this study innovatively designed two types of micro-groove textures on the tool surface based on the natural flow direction of chips: one parallel to and the other perpendicular to the main cutting edge (micro-texture width: 50 µm, micro-texture depth: 50 µm, micro-texture edge distance (distance from the main cutting edge): 200 µm, micro-texture spacing: 200 µm). At a cutting speed of 1250 r/min, a feed rate of 0.15 mm/r, and a cutting depth of 0.1 mm, Through finite element simulation analysis of cutting force, temperature, stress, and chip morphology, and using laser processing technology to precisely prepare micro-textured tools for actual cutting experiments, the study systematically evaluated the impact of microtextures on performance. Furthermore, this study integrated composite solid lubricants into the microgrooves to develop self-lubricating tools and investigated the synergistic effects of cutting speed and lubrication conditions on the performance of micro-textured tools. The results showed that micro-textured tools significantly reduced cutting force, stress, and temperature, improving friction and heat dissipation. Among them, self-lubricating micro-textured tools performed particularly well, further reducing cutting force (with a maximum reduction of 20.39%), improving surface quality (roughness of 1.421 µm), and optimizing chip morphology. The novelty of this study lies in the synergistic optimization of heat dissipation, friction reduction, and chip removal performance through micro-texture orientation design and solid lubricant-assisted machining. This technology provides an effective solution for enhancing the efficiency and quality of aluminium alloy machining.