Tool wear progression and its effects on energy consumption and surface roughness in cryogenic assisted turning of Ti-6Al-4V

Abstract

This work evaluates the machinability improvements in vastly used titanium alloy (Ti-6Al-4V) using alternate turning techniques. Detailed examination of flank and crater faces of inserts is carried out in this work to analyze tool wear under dry, wet, and cryogenic environments. Critical responses such as crater wear and energy consumption decide the machinability of materials, but these responses are less explored in the past using altered cutting conditions. This investigation analyzes the machinability in terms of industry-relevant responses such as tool wear, energy consumption, chip reduction coefficient, and average surface roughness under altered cutting conditions. Outcomes of this investigation show increase in tool life by 200% and 80% using cryogenic turning than in dry and wet turning techniques, respectively. Moreover, the findings of the study show up to 9% and 61% decline in energy consumption using cryogenic turning than in dry and wet turning, respectively. Surface roughness values also show a reduction by up to 71% and 64%, under cryogenic environment than in dry and wet environments, respectively. The results of this study advocate the suitability of cryogenic turning at industry-relevant parameters to establish this technique as a viable alternative to replace inefficient conventional turning techniques.