Numerical analysis of performance of different micro-grooved tools for cutting titanium alloy Ti-6Al-4V

Abstract

To achieve a better performance, a novel cutting tool has been developed with micro-grooves on its rake face. Such tools have great potential in manufacturing. However, micro-grooves of improper directions and shapes may adversely affect cutting tools. This paper investigates the performance of newly designed cemented carbide (WC/Co) cutting tools with micro-grooves on the rake face in the machining of titanium alloy Ti-6A1-4V using finite element (FEM) simulation. The objectives are to explore the influence of the directions and geometrical shapes of micro-grooves on the performance of cutting tools in dry turning of the titanium alloy and to compare it with conventional cutting tools. Specifically, the following aspects are compared: cutting temperature, cutting force, chip morphology, and stress distribution. It is found that these micro-grooved cutting tools generate lower cutting force and cutting temperature and increase chip curling. The maximum reduction of cutting force and cutting temperature occurs under different machining parameters. Compared with linear micro-grooves, the curvilinear micro-grooves diffuse the tool stress and weaken the stress concentration on cutting edges. In addition, the secondary cutting phenomenon of micro-grooved tools is analyzed, which can be effectively alleviated by reducing the width of micro-grooves and setting a reasonable radius of the secondary cutting edge.