Progressive tool-wear in machining with coated grooved tools and its correlation with cutting temperature

Abstract

This paper presents a detailed analysis of tool-wear progression through an experimental study of orthogonal machining of AISI 1045 steel with coated (TiN/TiCN/TiC) grooved tools. Transient infrared temperature measurements during the orthogonal cutting process have been obtained along with measurement of corresponding progressive tool-wear when turning using coated grooved tools under dry machining conditions. Simultaneously, two cutting force components were also recorded. The results obtained enabled the understanding of the modes of tool-wear, and helped to verify the effects of tool-chip interfacial temperature. This time-dependent study of tool-wear with the concurrent tool-chip interface temperature distributions reveals the relationship between the maximum tool temperature and the location of the maximum tool-wear rate at any given point in time. Scanning electron microscopic (SEM) analysis clearly shows the different dominant wear regions at different stages of machining with coated grooved tools. In this study, concurrent progression of flank wear (VB), secondary wall wear (SW, SD), and groove backwall wear (BW, KT) are examined. Finally, interrelationships between the progressive tool-wear, cutting temperature and the cutting forces are established experimentally, providing a framework for further studies.