Effect of Micro-Textured Tool Parameters on Forces, Stresses, Wear Rate, and Variable Friction in Titanium Alloy Machining

Micro-textures applied to cutting tool surfaces provide certain advantages such as reducing tool forces, stresses, and temperature hence overall friction between the tool–chip contact and improving chip adherence and associated tool wear. This study explores the effect of micro-texture geometry parameters fabricated on the rake face of tungsten carbide inserts that were tested in dry turning titanium alloy Ti-6Al-4V. The effects of micro-texture geometry on the cutting forces, tool stresses, tool temperatures, tool wear rate, and variable friction coefficient were studied with 3D finite element (FE) simulations. The simulation model was validated comparing cutting forces predicted and measured. The results indicated some effects of micro-textured tool geometry parameters being significant and others are not as significant. The experiments reveal that the effects of micro-groove width, depth, and distance from cutting edge are found to be significant on cutting forces, but the spacing is not as much. The effect of increasing feed rate on cutting force and tool wear was significant and suppressed the advantages offered by micro-grooved texture tool geometry. The simulation results indicate that the effect of micro-texture parameters such as groove depth and distance from cutting edge is significant on tool temperature and wear rate. The variable nature of friction coefficient was emphasized and represented as functions of state variables such as normal stress and local temperature as well as micro-texture parameters.