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. The cuticle of desert scorpions exhibits periodic ridge–groove microstructures that regulate contact and reduce resistance during locomotion over solid terrains. 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 exhibited a 1–6 °C reduction in temperature rise, up to 50% reduction in wear, corresponding to nearly 100% improvement in effective tool life, along with significantly improved surface finish at higher machining parameters. The improvements are attributed to reduced real contact area, suppression of adhesive junction formation, and debris entrapment, mechanisms analogous to 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.