Multi-pattern failure modes and wear mechanisms of WC-Co tools in dry turning Ti–6Al–4V

Abstract

Tool wear and catastrophic failure are key issues in industrial manufacturing process due to increasing the production costs and destroying the surface quality. A series of multiple factors including physical process, chemical reaction and thermo-mechanical phenomena are responsible for the occurrence of tool wear process. The aim of this work focused on the multi-pattern analysis of failure modes and wear mechanisms during turning titanium alloy Ti–6Al–4V with the ultrafine cemented carbide cutting tool. Firstly, tool failure modes were investigated categorically according to the various wear regions including cutting edges, rake faces, and flank faces. The normal wear modes such as crater wear, flank wear, BUE, micro-chipping and abnormal wear modes including plastic deformation, flaking, and catastrophic failure were described in detail. Secondly, the tool wear mechanisms were analyzed, including the mechanical-induced abrasion, heat-induced adhesion and diffusion, chemical-induced oxidation. Depending on the cutting conditions, the tool wear mechanisms were the combination of various wear factors, and single or multiple factors might dominate in the cutting process. According to the failure modes and wear mechanisms, a comprehensive evolution mapping of tool wear process was established to explain the relationships among machining process, failure modes, and wear mechanisms. This work provided important experimental basis for designing tool materials and developing high-speed cutting technology.