Current Concepts in Engineering Research and Technology Vol. 2

Despite extensive research on cutting tool wear during machining, accurately quantifying wear remains difficult due to the complex wear process, which limits the establishment of a universal wear equation. This study presents a novel design of coated cutting tools featuring a crater-like (undulating) surface topography produced by Electrical Discharge Machining (EDM) and coated with titanium nitride (TiN). The textured surface, characterised by peaks and valleys, enhances coating retention by trapping TiN within surface features, thereby improving wear resistance and tool life. Experimental results show that EDMed TiN-coated inserts outperform conventional TiN-coated tools, achieving up to 40% higher cutting speeds, 60% longer tool life, and reduced power consumption. These improvements are attributed to reduced friction and improved tribological conditions at the tool–chip and tool–workpiece interfaces, resulting in lower heat generation and delayed wear progression. The findings demonstrate that surface texturing combined with hard coatings enables the use of higher cutting speeds, feeds, and depths of cut, leading to increased material removal rates and enhanced productivity. This work provides practical insights for improving the performance of coated cutting tools in modern machining applications. The study explores tool wear behaviour and analyses it within a tribological framework to elucidate the underlying friction and wear mechanisms.