Abstract
Asymmetrical cutting edges have been proven to influence the resulting surface layer states of machined metal parts. As machining of Ti6Al4V alloy is subject to rather high tool wear, tool geometry changes during machining can influence the resulting surface layer states like residual stresses and nanocrystalline surface layer depth. In this paper, the influence of asymmetric cutting edge microgeometries (characterized by form-factor) and different process parameters on the resulting surface layer microstructure of Ti6Al4V is investigated through face turning experiments and focused ion beam analyses. 2D-FE simulations are conducted using the software Simufact Forming, and a Johnson-Cook model with triaxiality based damage criterion. According to the known mechanisms of grain refinement, mechanical and thermal states are analyzed and related to the experimental data. Relative roundness higher than one, and form-factors smaller than one lead to severe surface layer deformation and increased recrystallization depths, with the effect of form-factor clearly dominating compared to relative roundness.
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