Performance investigation of cryogenic treated-double tempered cutting inserts in dry turning of Ti–6Al–4V alloy

Abstract

Dry machining of Titanium alloy Grade 5 (Ti–6Al–4V) with cryogenic treated, double-tempered KC5010 cutting inserts was examined. The impact of cryogenic treatment followed by tempering of the carbide inserts was investigated using microstructure analyses. The effects of constant depth of cut, cutting speed, and feed rate on machining variables (torque, force, surface roughness, temperature, and tool wear) were investigated. According to the experimental results, the cutting speed is the most important parameter that has a direct influence on the machining characteristics. Increased cutting speed and feed rate generate larger tangential pressures, allowing for a reduction in chip contact length; a shorter contact length results in reduced surface roughness and flank wear rate, respectively. The effects of cutting speed and feed rate on chip thickness were studied. Image analysis of the segmented chip was used to investigate the form and size of the saw-tooth profile of serrated chips. It was discovered that raising the cutting speed from 73 m/min to 160 m/min enhanced the free surface lamella of the chips and improved the visibility of the saw tooth segment. As cutting speed increases, all response parameters (torque, temperature, force, tool wear, and surface roughness) increase at the same time, by nearly 300%. Deep cryogenic treatment enhanced micro-hardness, resistance to wear, and toughness. As a result, there was reduced flank wear with tiny abrasion lines. Lower cutting speeds and feed rates resulted in less rake surface wear. Finally, the current study's convergence with earlier research was presented, indicating strong agreement between the two examinations.