Finite element asnalysis of Ti1-xAlxN coated tools cutting performance and tool wear during Ti–6Al–4V milling

Abstract

Ti–6Al–4V alloy, as a typical difficult-to-machine material, is prone to problems such as large cutting forces, high cutting temperatures, and serious tool wear during the cutting process. Ti1-xAlxN coated tools are widely used in machining Ti–6Al–4V alloys. The main wear forms of Ti1-xAlxN coated tools are coating cracking and delamination. After the coating has been delaminated, the tool substrate is in direct contact with the workpiece material, aggravating tool wear and shortening the tool life. Therefore, the milling process of Ti1-xAlxN coated tool cutting Ti–6Al–4V alloy was performed using FEM. The effects of Al contents (Ti0·48Al0·52N, Ti0·38Al0·62N), coating thickness (2, 3, 4 μm), and tool substrate (Cemented Carbide Grade K, M, P) of Ti1-xAlxN coated tools on the cutting performance (cutting force, cutting temperature, maximum principal stress, the temperature and stress of coating-substrate interface) and tool wear were discussed. The influence of the maximum principal stress, the temperature and stress of coating-substrate interface on tool wear were analyzed. This paper can provide a reference for the design and optimization of Ti1-xAlxN coated tools by investigating the wear of Ti1-xAlxN coated tools cutting titanium alloys, which can be used to slow tool wear and prolong tool life.