The optimization of a broach surface is of great significance to improve the cutting performance of the tool. However, the traditional optimization method (surface texture, coating, etc.) destroys the stress distribution of the tool and reduces the service life of the tool. To avoid these problems, four kinds of flocking surfaces (FB1, FB2, FB3, and FB4), imitating the biological structure of Daphniphyllum calycinum Benth (DCB), were fabricated on the rake face of the broach by electrostatic flocking. The broaching experiment, wettability, and spreading experiment were then conducted. Moreover, the mathematical model of the friction coefficient of the bionic broach was built. The effect of broaches with different flocking surfaces on the broaching force, chip morphology, and surface quality of workpieces was studied. The results indicate that the flocked broaches (FB) with good lubricity and capacity of microchips removal (CMR) present a smaller cutting force (Fc) and positive pressure (Ft) compared to the unflocked broach (NB), and reduce the friction coefficient (COF). The chip curl was decreased, and the shear angle was increased by FB, which were attributed to the function of absorbing lubricant, storing, and sweeping microchips. Its vibration suppression effect enhanced the stability in the broaching process and improved the surface quality of the workpiece. More importantly, the FB2 with the most reasonable fluff area and spacing exhibited the best cutting performance. The experimental conclusions and methods of this paper can provide a new research idea for functional structure tools.
Keywords: 7075 aluminum alloy; bionics; broaching performance; flocked broach; mathematical model.