Improving dry machining performance of surface modified cutting tools through combined effect of texture and TiN-WS2 coating

Abstract

In this research work, investigation on different surface modification techniques on cutting tools such as TiN-WS2 coating (T2), textured cutting tool (T3) and TiN-WS2 coated textured tool (T4) in dry machining of Ti-6Al-4V has been carried out and compared with commercial tool (T1). The presence of (002) orientation corresponding WS2 was observed in the diffraction pattern and this in turn was said to provide lubricity properties to the coatings. The cutting force generated during machining was reduced by 14 % for T4 tool when compared to T1. The T4 tool showed an increase in the shear angle by 7.5 % and decrease in coefficient of friction by 47 %. The prime mechanism attributed to the better performance of cutting tool was reduced tool-chip contact length. The T4 tools showed a 13 % reduction in tool-chip contact length when compared to commercial tools. The tool life of the T2, T3 and T4 tools was improved by 35 %, 29 % and 43 % respectively in comparison to commercial tools. The TiN-WS2 coatings, through its effective lubricity properties have said to nullify the effect of coating affinity between the tool and workpiece as evidenced by the absence of built-up edge on the tool rake face while machining using TiN-WS2 coated tool. The combined effect of TiN-WS2 coatings and surface textures have resulted in better machining characteristics, suggesting it as a suitable surface modification for dry machining of Ti-6Al-4V.