Textured Tools and Cryogenic Cooling for Modifying Chip Morphology in PEEK Machining

PEEK is a high-performance polymer widely used for biomedical applications, but its machinability remains a critical issue. Traditional coolants are unsuitable for biomedical use, and dry machining produces long, entangled chips that hinder surface quality. Cryogenic machining has been recently introduced for PEEK chip breaking. Textured tools can be exploited to modify the chip formation further. In this context, the study examines the effects of tool rake face texturing on chip formation in cryogenic and dry cutting conditions. Turning trials were conducted with plain and laser-textured tools with grooves of different geometry at varying depths of cut. The results indicate that cryogenic cooling promotes chip breakage, with textured tools enhancing the fragmentation process. A correlation was observed between groove design and chip morphology, highlighting the potential of these solutions to improve machining efficiency.