Scorpion-inspired flank surface texturing for biomimetic reduction of frictional heating and wear in dry turning

Natural arthropod cuticles exhibit micro-scale surface features that reduce drag and control interfacial interactions during motion. In particular, the cuticle of desert scorpions bears periodic ridge–groove microstructures that regulate contact and reduce resistance during locomotion over solid terrain. Inspired by the micro-topography of scorpion skin, this study translates a biological surface concept into a functional engineering solution for tribological control in dry machining. Bioinspired micro-grooves with 0.2 mm spacing were fabricated on the flank surface of tungsten carbide inserts using Nd:YAG laser texturing. A comparative experimental investigation between conventional and textured inserts was conducted during dry turning of C-20 steel over a wide range of spindle speeds, feed rates, and depths of cut. Tool performance was quantified through tool-tip temperature rise, insert wear by weight loss, SEM wear morphology, and 3D surface profilometry of the machined workpiece. The biomimetic textured inserts achieved a reduction of 1 °C–6 °C in temperature rise and a reduction in wear of up to 50%, corresponding to an improvement of approximately 96% in effective tool life under high-feed cutting conditions (775 rpm, 1.6 mm rev⁻¹). The improvements are attributed to reduced real contact area, suppression of adhesive junction formation, and debris entrapment, mechanisms analogous to the drag-reduction strategies observed in scorpion cuticle morphology. The study demonstrates how bioinspired surface architecture can be functionally transferred to cutting tools to achieve measurable tribological and thermal benefits in a practical engineering process.