Efficiency investigations of textured cutting tools in orthogonal cutting of Ti6Al4V alloy: a numerical approach

Abstract

This paper investigates efficiency of micro-textured cutting tools in dry orthogonal turning of Ti6Al4V alloy using 2D numerical analysis. For this purpose, micro-grooves at different sizes were generated on rake face of cutting tools. Then, orthogonal cutting simulations were conducted using different tool rake angle values. Contact length at tool-chip interface, cutting force and force ratio results were evaluated focusing on performance of micro grooves. The aim was to improve process efficiency and minimize negative environmental impacts by contributing knowledge in development of textured cutting tools. The simulation results revealed that decreased 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.