Evaluating the effectiveness of the novel surface textured tools in enhancing the machinability of titanium alloy (Ti6Al4V)

Abstract

The effectiveness of the novel micro textured tools developed as an attempt to improve the machinability of Ti6Al4V material is studied. Different types of textures were developed on the rake face of the tools and subsequently coated with a solid lubricant (tungsten disulfide). Square and circular textures are developed for the first time. The textured and coated tools were used for machining Ti6Al4V. Adhesion of the material to the rake face of the tools is observed to be decreased considerably although not eliminated completely. Maximum reduction in the main cutting force was 60% for the square textured tools. Friction at the rake face of the tool is reduced considerably which results in the improvement of tool life. The change in adhesion behaviour and the observed reduction in cutting forces are attributed to the reduction in chip-tool contact area owing to the surface texture on the tool inserts. Further, these textures are acting as reservoirs of solid lubricant. Chip morphology is also found to be favourably altered through the reduction in the segmentation frequency (about 40% for square textured tools and 27% for linear textured tools).

Keywords

• dry machining
• tungsten disulfide
• textured tools
• focused ion beam machining