Efficiency investigations of textured cutting tools in orthogonal cutting of Ti6Al4V alloy: a numerical approach
Efficiency investigations of textured cutting tools in orthogonal cutting of Ti6Al4V alloy: a numerical approach
This paper investigates efficiency of micro-textured cutting tools in dry orthogonal turning of Ti6Al4V alloy using 2D numericalanalysis. For this purpose, micro-grooves at different sizes were generated on rake face of cutting tools. Then, orthogonal cuttingsimulations were conducted using different tool rake angle values. Contact length at tool-chip interface, cutting force and force ratioresults were evaluated focusing on performance of micro grooves. The aim was to improve process efficiency and minimize negativeenvironmental impacts by contributing knowledge in development of textured cutting tools. The simulation results revealed thatdecreased forces, force ratio and contact length is possible with use of textured cutting tools. However, improper selection of texture parameters may cause adverse effects such as increased friction. Accordingly, efficiency of micro-grooves relies on both, groove size and rake angle.
___
- Hong, S.Y., I. Markus, and W.-c. Jeong, New cooling
approach and tool life improvement in cryogenic machining of
titanium alloy Ti-6Al-4V. International Journal of Machine Tools
and Manufacture, 2001. 41(15): p. 2245-2260.
- Arrazola, P.-J., et al., Machinability of titanium alloys
(Ti6Al4V and Ti555. 3). Journal of materials processing
technology, 2009. 209(5): p. 2223-2230.
- Ezugwu, E.O. and Z.M. Wang, Titanium alloys and their
machinability—a review. Journal of Materials Processing
Technology, 1997. 68(3): p. 262-274.
- Su, Y., et al., Cutting performance of micro-textured
polycrystalline diamond tool in dry cutting. Journal of
Manufacturing Processes, 2017. 27: p. 1-7.
- Arulkirubakaran, D., V. Senthilkumar, and V. Kumawat,
Effect of micro-textured tools on machining of Ti–6Al–4V alloy:
an experimental and numerical approach. International Journal
of Refractory Metals and Hard Materials, 2016. 54: p. 165-177.
- Obikawa, T., et al., Micro-texture at the coated tool face for
high performance cutting. International Journal of Machine Tools
and Manufacture, 2011. 51(12): p. 966-972.
- Xing, Y., et al., Cutting performance and wear mechanism of
nanoscale and microscale textured Al2O3/TiC ceramic tools in
dry cutting of hardened steel. International Journal of Refractory
Metals and Hard Materials, 2014. 43: p. 46-58.
- Ma, J., et al., FEM assessment of performance of microhole
textured cutting tool in dry machining of Ti-6Al-4V. The
International Journal of Advanced Manufacturing Technology,
2016. 84(9-12): p. 2609-2621.
- Deform-2D, Version 11 User Manual. STFC, Columbus,
Ohio State, USA, 2014.
- Johnson, G.R. and W.H. Cook, Fracture characteristics of
three metals subjected to various strains, strain rates,
temperatures and pressures. Engineering fracture mechanics,
1985. 21(1): p. 31-48.
- Lee, W.-S. and C.-F. Lin, High-temperature deformation
behaviour of Ti6Al4V alloy evaluated by high strain-rate
compression tests. Journal of Materials Processing Technology,
1998. 75(1-3): p. 127-136.
- Kawasegi, N., et al., Development of cutting tools with
microscale and nanoscale textures to improve frictional behavior.
Precision Engineering, 2009. 33(3): p. 248-254.
- Özel, T., et al., Investigations on the effects of multi-layered
coated inserts in machining Ti–6Al–4V alloy with experiments
and finite element simulations. CIRP Annals, 2010. 59(1): p. 77-
82.
- Kaya, E., F. Çakır, and Y. Özdemir, Investigations on the
orthogonal cutting behavior of Ti6AL4V with micro-textured tool
geometries using finite element method in International
Conference on Mechanical and Aerospace Engineering. 2017:
MA, USA. p. 8-12.
- Chen, Z.M., et al. A simulation study on the effect of microtextured
tools during orthogonal cutting of titanium alloy Ti-6Al4V.
in Applied Mechanics and Materials. 2013. Trans Tech Publ.
- Choudhury, S.K. and K.K. Kishore, Tool wear measurement
in turning using force ratio. International Journal of Machine
Tools and Manufacture, 2000. 40(6): p. 899-909.
- Devillez, A., et al., Cutting forces and wear in dry machining
of Inconel 718 with coated carbide tools. Wear, 2007. 262(7): p.
931-942.
- Shaw, M.C. and J. Cookson, Metal cutting principles. 1984:
Clarendon press Oxford.
- Ma, J., N.H. Duong, and S. Lei, 3D numerical investigation
of the performance of microgroove textured cutting tool in dry
machining of Ti-6Al-4V. The international journal of advanced
manufacturing technology, 2015. 79(5-8): p. 1313-1323.