3D numerical investigation of the performance of microgroove textured cutting tool in dry machining of Ti-6Al-4V

In this paper, the performance of microgroove textured cutting tools in dry three-dimensional (3D) turning of Ti alloy (Ti-6Al-4V) is investigated using AdvantEdge finite element simulation. Microgrooves are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purposes are to examine the effect of microgroove textured cutting tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microgroove parameters are examined: microgroove width, microgroove depth, and edge distance (the distance from cutting edge to the first microgroove). Their effects are assessed in terms of the cutting forces and chip-tool contact length. It is found that microgroove textured cutting tools generate lower cutting forces and consequently lower the energy consumption for machining. The microgroove width, microgroove depth, and edge distance all have influence on cutting forces in their own ways. This research provides insightful guidance for optimizing cutting tools in terms of cutting forces and energy consumption.