Effect of textures on machining of Ti-6Al-4V alloy for coated and uncoated tools: A numerical comparison

The present investigation is to reduce the detrimental effects happened during machining of Ti6Al4V by employing different types of texture patterns on the rake face of the coated (TiN and TiAlN) and uncoated cutting tool inserts. During 3D-Deform machining simulation, the work material is constrained as elasto-plastic and the tool material constrained as rigid body. The machining simulation process was carried out with the updated Lagrangian formulation, and Johnson-Cook model was used to predict the machining forces, cutting temperature and shear angle. A semi-solid lubricant, molybdenum disulfide with SAE40 oil (80:20), was applied during the process and the temperature at the tool-chip interface zone was measured with the aid of a thermal imager camera. Kistler 9257B type three component dynamometer was used to measure the machining forces. The measured machining forces, temperature and shear angle were compared with the results of 3D-Deform simulation. Comparatively, it was found that the cutting force and temperature were found to be minimum during machining of Ti6Al4V alloy with TiAlN-coated perpendicular textured tool.