Improve Tool Performance Research Articles

Performance Analysis of TiAlN/TiN PVD Coated Carbide Tools in High-Speed and Dry Machining of AISI 1070 Alloy Steel

This study investigates the performance of TiAlN/TiN PVD-coated carbide tools in high-speed, dry machining of AISI 1070 alloy steel. AISI 1070 is a high-carbon steel known for its exceptional hardness, making tool wear a significant challenge. The research focuses on evaluating tool wear, wear mechanisms, and optimal cutting parameters. Quantitative assessments of flank wear (VB) were conducted, alongside detailed Scanning Electron Microscopy (SEM) analyses to identify the primary wear mechanisms, such as abrasion and adhesion. The study determined that the optimal cutting conditions for minimal tool wear include a cutting speed of 231 m/min, a feed rate of 0.1 mm/rev, and a depth of cut of 1 mm. The TiAlN/TiN coatings significantly enhanced the tools' wear resistance and longevity, maintaining their cutting-edge sharpness under strenuous conditions. Additionally, the coatings effectively minimized the formation of white layers on the machined surface, preserving the mechanical properties and surface integrity of the alloy. These findings demonstrate the coatings' superiority in reducing friction and heat generation during high-speed machining. The study provides valuable insights for industrial applications, highlighting the potential of TiAlN/TiN-coated carbide tools to improve tool performance, operational efficiency, and overall productivity in high-speed machining environments.

A Tribological Study of CrN and TiBN Hard Coatings Deposited on Cobalt Alloys Employed in the Food Industry

In this work, a comparative study of the tribological performance of two hard coatings, CrN/TiBN, was conducted for research purposes and industrial applications in food products, particularly for food packaging into cans using the double hermetic sealing process. CrN and TiBN coatings were successfully deposited on a base-cobalt metal substrate of a CoCrW commercial alloy using physical vapor deposition by arc evaporation (AEPVD) technology to improve the tribological properties of the commercial alloy, including wear and corrosion resistance, lower coefficient of friction, and overall durability. This research focuses on conducting scratch and abrasion wear resistance tests in dry conditions; specifically, it pursues to evaluate the wear corrosion properties, known as tribocorrosion performance, on CrN/TiBN hard coatings. The experimental results show that the CrN coating (2.9 μm) is slightly thicker than the TiBN coating (2.7 μm), with a 47 N critical load. It also shows a lower coefficient of friction (CoF) in a dry environment, while the TiBN coating showed total detachment and a high coefficient of friction in a dry environment condition. Tribocorrosion testing in brine aqueous solution indicated that CrN coating shows a high friction coefficient with a higher open circuit potential value (Ecorr), and TiBN shows the lowest corrosion potential (Ecorr) and the lowest friction coefficient. This suggests that CrN could provide better corrosion protection for commercial cobalt alloys and improve tool performance during the food canning process in brine environments.

Tool Condition Monitoring in the Milling Process Using Deep Learning and Reinforcement Learning

Tool condition monitoring (TCM) is crucial in the machining process to confirm product quality as well as process efficiency and minimize downtime. Traditional methods for TCM, while effective to a degree, often fall short in real-time adaptability and predictive accuracy. This research work aims to advance the state-of-the-art methods in predictive maintenance for TCM and improve tool performance and reliability during the milling process. The present work investigates the application of Deep Learning (DL) and Reinforcement Learning (RL) techniques to monitor tool conditions in milling operations. DL models, including Long Short-Term Memory (LSTM) networks, Feed Forward Neural Networks (FFNN), and RL models, including Q-learning and SARSA, are employed to classify tool conditions from the vibration sensor. The performance of the selected DL and RL algorithms is evaluated through performance metrics like confusion matrix, recall, precision, F1 score, and Receiver Operating Characteristics (ROC) curves. The results revealed that RL based on SARSA outperformed other algorithms. The overall classification accuracies for LSTM, FFNN, Q-learning, and SARSA were 94.85%, 98.16%, 98.50%, and 98.66%, respectively. In regard to predicting tool conditions accurately and thereby enhancing overall process efficiency, SARSA showed the best performance, followed by Q-learning, FFNN, and LSTM. This work contributes to the advancement of TCM systems, highlighting the potential of DL and RL techniques to revolutionize manufacturing processes in the era of Industry 5.0.

Investigation of different abrasive jet machining methods applied to milling tool coatings for post-treatment

Post-processing of tool coatings is an essential way to remove defects, enhance coating properties, and improve tool performance, where abrasive jet machining plays an important role. This paper introduces a novel application of self-developed elastic abrasives to the post-treatment of coated tools, with a comparison against hard abrasive (Al2O3) jet machining (HAJM). The results demonstrate that EAJM significantly reduces the surface roughness of the coating and enhances the wear resistance of milling tools across a wide range of jetting parameters without damaging the coating. Conversely, HAJM yields more pronounced improvements in physical properties such as coating hardness, elastic modulus, and residual stress, and also significantly enhances tool performance, albeit with a need for precise process parameters. Overly aggressive HAJM parameters can lead to diminished coating performance and reduced tool life. Additionally, the study reveals that the improvement in tool life is closely linked to the physical properties of the coating, which contributes to the enhanced performance observed with HAJM-treated tools. To further investigate this, a mathematical model was established to analyze the coupling effect of jet pressure and time on tool life. The proposed model identifies the optimal ranges of the jetting coefficient for HAJM and EAJM as 326–4870 kPa·s and 1061–17,780 kPa·s, respectively, offering a novel approach to optimizing tool performance and life.

Improving Tool Performance in Turning Hard Stainless Steels

Improving Tool Performance in Turning Hard Stainless Steels

Re-Desain Alat Pencacah yang Ergonomis Guna Mempercepat Waktu Proses Produksi pupuk Cair Organik

A chopper is a tool used to chop or crush materials into smaller and finer pieces. In papungan village, a shredding tool is used to chop the materials used for making liquid organic fertilizer, this is because the high cost of chemical fertilizers is one of the reasons farmers switch to organic fertilizers. The shredding tool that has been designed has several obstacles, one of which is the most prominent, namely when chopping fibrous materials, the machine falters and even dies, so it is necessary to re-design the tool. The purpose of this re-design is to solve the problems experienced by the tool. There are several changes and additions to the tool to solve problems and improve tool performance. The redesigned tool can speed up production time 58,6%/2,4x and the resulting chopping is smoother than the previous tool.

Exploring the diffusion wear mechanism between SiAlON and Inconel 718: Interfacial reactions and thermal properties in diffusion couples

During the machining of Inconel 718 using SiAlON ceramics, the tool life can be significantly influenced by diffusion wear. To investigate this crucial wear behavior, this study focuses on the thermochemical interactions in the diffusion couple between SiAlON ceramics and Inconel 718 superalloy. So, we examine the microstructural characteristics and phase formation behavior in the reacted layer between these two materials. The interfaces between these two materials exhibit distinguishable elemental contrasts and phase formations. Particularly, the phases indicate vitrification or devitrification in the diffusion layer, influenced by the chemical composition. This issue in the diffusion couple was analyzed with thermophysical properties using light flash analysis (LFA). After, it was confirmed that the vitrification of the diffusion layer can be induced by the conduction behavior of heat trapped between SiAlON and Inconel 718 during supercooling. These characterizations verify that the devitrification of the welding layer (diffusion layer), resulting from the reaction between SiAlON ceramics and Inconel 718 superalloy, can depend on the thermal conductivity of the prepared ceramics. Furthermore, we discovered a possibility that this could contribute to improving tool performance by suppressing diffusion wear.

Analysis of Contact Thermal Resistance and the Use of Coatings on Heat Transfer in Cemented Carbide Metal Cutting Tools

Objective: The objective of this study is to investigate the thermal behavior of coated cutting tools in industrial turning processes, aiming to enhance machining efficiency and prolong tool lifespan. Theoretical Framework: The study is grounded in the concepts of heat transfer, thermally insulating coatings, and their impact on cutting tool performance. Key theories and models include thermal conductivity, thermal insulation, and heat dissipation mechanisms. Methodology: The research employs numerical simulation using the COMSOL® Multiphysics package to model transient heat transfer within coated tools and their holders. Thermal contact resistance at the tool-holder interface is also considered. Two coating configurations (Model 1 and Model 2) with different materials are analyzed, resulting in six simulation scenarios. Results and Discussion: The simulations demonstrate significant temperature reductions in the coated tools compared to uncoated ones, with Model 2 showing the most substantial decrease. These findings indicate the effectiveness of thermally insulating coatings in mitigating heat generation and improving tool performance. Research Implications: The study's findings have practical implications for the manufacturing industry, suggesting that the use of specific coatings can lead to higher cutting velocities and prolonged tool lifespan. These insights can inform decision-making in tool selection and process optimization. Originality/Value: This research contributes to the literature by providing a detailed analysis of the thermal behavior of coated cutting tools under extreme temperatures. The study's innovative approach and practical implications offer valuable insights for improving machining processes and tool performance.

An Investigation into the Surface Integrity of Micro-Machined High-Speed Steel and Tungsten Carbide Cutting Tools.

The performance and lifespan of cutting tools are significantly influenced by their surface quality. The present report highlights recent advances in enhancing the surface characteristics of tungsten carbide and high-speed steel cutting tools using a novel micro-machining technique for polishing and edge-honing. Notably, the main aim was to reduce the surface roughness while maintaining the hardness of the materials at an optimal level. By conducting a thorough analysis of surfaces obtained using different techniques, it was found that the micro-machining method effectively decreased the surface roughness of the cutting tools the most effectively out of the techniques investigated. Significantly, the surface roughness was reduced from an initial measurement of 400 nm to an impressive value of 60 nm. No significant change in hardness was observed, which guarantees the maintenance of the mechanical properties of the cutting tools. This analysis enhances the comprehension of surface enhancement methodologies for cutting tools through the presentation of these findings. The observed decrease in surface roughness, along with the consistent hardness, exhibits potential for improving tool performance. These enhancements possess the capacity to optimise manufacturing processes, increase tool reliability, and minimise waste generation.

Ultra-short pulsed laser processing of single crystalline diamonds for tooling applications

This study investigates the feasibility of using ultra-short pulsed (USP) lasers to fabricate single crystalline diamond (SCD) tools. SCD has exceptional mechanical, tribological, and thermal properties and offers excellent performance in the precision machining of hard and brittle materials over polycrystalline diamond and diamond-coated tools. However, the anisotropic nature of the SCD makes it difficult for laser machining because the material shows susceptibility to cracking, defect growth, and breakout depending on its crystallographic orientation. Anisotropy needs to be considered while optimizing the geometry of the tool to minimize wear and improve tool performance. An advanced four-axis laser machining approach with optimized laser parameters and temporal beam shaping is used to mitigate challenges related to defect growth and orientation dependence, leading to the production of high-quality single cutting-edge SCD tools. Cylindrical diamonds and diamond crystals with top surface planes {100} and {111} are used in the study. The occurrence of defects in the diamond when laser machined and their dependence on the crystallographic orientation along the circumference of the diamond is thoroughly investigated via SEM, electron backscatter diffraction, and light microscopy images. Finally, the laser-manufactured SCD tools are tested by turning fully sintered zirconia ceramics (3Y-TZP-A). USP laser machining of SCD is demonstrated to be a viable alternative to traditional manufacturing methods for producing high-quality SCD tools with unique properties and performance. The results further emphasize the importance of understanding the crystallographic orientation dependence when laser machining crystalline materials like diamonds.

Performances of cryo-treated and untreated cutting tools in machining of AA7075 aerospace aluminium alloy

The quality of drilled holes in aluminium alloys used in the aerospace industry is vital to ensure high-precision structural integrity. For this reason, optimum selection of cost-effective cutting tools and cutting parameters is of great importance. Nowadays, due to their high cost and supply difficulties, there is a great interest in improving the performance of traditional HSS cutting tools as an alternative to ceramic, carbide and coated cutting tools. HSS cutting tools are widely used in different industries due to their cost-effectiveness and suitability to improve tool performance. In this research, the performances of cryo-treated (DC&T) and untreated (UT) HSS cutting tools used in dry machining of AA7075 aluminium alloys were investigated. Thanks to DC&T processes applied to HSS cutting tool, improvements have occurred in its microstructure. The hardness value of HSS cutting tool increased by 6.89% with the effect of DC&T processes applied. When the highest and lowest Ra values obtained using DC&T and UT HSS cutting tools were compared, it was seen that DC&T HSS cutting tool performed better by 11.05% and 25.91%, respectively. It has been determined that the hole surface quality of the aluminium workpiece machined with DC&T and UT HSS drills is negatively affected by the increase in spindle speed and feed rate. The highest S/N ratios calculated according to Ra values of holes drilled on aluminium workpieces using DC&T and UT HSS cutting tools were found to be -7.12 dB (2.27 μm) and -9.62 dB (3.03 μm), respectively. In the ANOVA analysis, it was determined that the most effective parameters on Ra values were spindle speed (70.62%), tools (18.19%) and feed rate (9.98%), respectively. In the regression analysis, R2 value for Ra values was calculated as 98.30%. High R2 value result shows that the model developed is quite successful in estimating Ra values.

Self-sharpening property of porous metal-bonded aggregated cBN wheels during the grinding of Ti–6Al–4V alloys

Grinding process with cubic boron nitride (cBN) superabrasive wheels has been the subject of extensive research during high efficiency and precision machining difficult-to-cut materials in aerospace and aviation industries. However, the grinding performance and tool-life of conventional cBN abrasive wheels are severely affected by the probable macro-fracture and pull-out of cBN grains owing to their anisotropic crystalline structure. In this case, porous metal-bonded grinding wheels coupled with high-performance aggregated cBN abrasive grains were developed to improve tool performance and machined surface integrity. Characterisation of morphologies, including as-sintered aggregated cBN abrasive grains, pore structures and grain wear evolutions, was performed. The grinding ratio, grinding forces, force ratio and ground surface roughness were evaluated through single-grain grinding of Ti–6Al–4V alloys. Experimental results indicated that the porous aggregated cBN wheels had abundant chip storage space and excellent wear resistance. A stable grinding force ratio and small ground surface roughness were obtained during the tool wear tests due to the combined characteristics of microfracture and partial macrofracture of multi-layer cBN particles.

Epoxy tooling: Technologies, developments, sustainability and future interest to industry 4.0

The technology of epoxy tooling, at present under continuous development, is used for the rapid manufacture of cost-effective tools for small batch production. It is a valid alternative with no need for expensive investment in metallic moulds for the development of new products. Current investigations are focused on improvements to the production system, improved tool performance, the cost reduction of moulds and tool manufacturing sustainability. In this paper, both the advantages and the disadvantages of epoxy tooling in injection moulding, wax injection, metal stamping and hot embossing are compared with conventional techniques. Following a brief introduction of rapid tooling technologies, the latest advances of epoxy tooling and their implementation in different manufacturing processes are all analysed. These developments refer to the production of new ad-hoc epoxy composites, increased productivity using conformal cooling channels, the reduction of the tooling manufacturing costs through waste reuse and the emerging industry 4.0 technologies for smart manufacturing and tooling. The main objective is to identify both the challenges facing epoxy tooling techniques and future research directions.

High performance peel grinding of steel shafts using coarse electroplated CBN grinding wheels

Grinding is widely known for its low material removal rates and high surface quality. However, recent developments in production processes for cubic boron nitride (CBN) abrasive grains have led to commercially available grain sizes larger than 300 µm. These superabrasive CBN-grains allow higher material removal rates during grinding of hardened steel components. Currently, these components are pre-machined with turning processes before hardening and finishing the work piece by grinding. However, the turning process can be eliminated by grinding with coarse CBN-grains since higher depths of cut are achievable when machining hardened components. This paper explores the limits of grinding wheels using grains with a size of B602 during soft and hard machining in comparison to conventional B252 grains. It is shown that the use of coarser grains leads to lower process forces, higher (tensile) residual stress and higher surface roughness. Residual stress and surface roughness are of less importance as these grains are to be used mainly in roughing operations with ensuing finishing operations for the required surface properties. Over all investigations, especially in hard machining, neither grain nor tool wear was observed for the B602 grains, whereas the B252 tool was severely clogged during the experiments. Additionally, the grinding force ratio indicates that the coarse grain tools have not yet reached their productivity limit as it increases over all investigated feeds. This indicates improving tool performance with lower amounts of rubbing for increasing feed rate during hard grinding and shows the potential for the industrial use of higher feed rates with larger grains.

Investigation of the Wear Behavior of PVD Coated Carbide Tools during Ti6Al4V Machining with Intensive Built Up Edge Formation

Tool wear phenomena during the machining of titanium alloys are very complex. Severe adhesive interaction at the tool chip interface, especially at low cutting speeds, leads to intensive Built Up Edge (BUE) formation. Additionally, a high cutting temperature causes rapid wear in the carbide inserts due to the low thermal conductivity of titanium alloys. The current research studies the effect of AlTiN and CrN PVD coatings deposited on cutting tools during the rough turning of a Ti6Al4V alloy with severe BUE formation. Tool wear characteristics were evaluated in detail using a Scanning Electron Microscope (SEM) and volumetric wear measurements. Chip morphology analysis was conducted to assess the in situ tribological performance of the coatings. A high temperature–heavy load tribometer that mimics machining conditions was used to analyze the frictional behavior of the coatings. The micromechanical properties of the coatings were also investigated to gain a better understanding of the coating performance. It was demonstrated that the CrN coating possess unique micromechanical properties and tribological adaptive characteristics that minimize BUE formation and significantly improve tool performance during the machining of the Ti6Al4V alloy.

Disease-specific variant pathogenicity prediction significantly improves variant interpretation in inherited cardiac conditions

PurposeAccurate discrimination of benign and pathogenic rare variation remains a priority for clinical genome interpretation. State-of-the-art machine learning variant prioritization tools are imprecise and ignore important parameters defining gene–disease relationships, e.g., distinct consequences of gain-of-function versus loss-of-function variants. We hypothesized that incorporating disease-specific information would improve tool performance. MethodsWe developed a disease-specific variant classifier, CardioBoost, that estimates the probability of pathogenicity for rare missense variants in inherited cardiomyopathies and arrhythmias. We assessed CardioBoost’s ability to discriminate known pathogenic from benign variants, prioritize disease-associated variants, and stratify patient outcomes. ResultsCardioBoost has high global discrimination accuracy (precision recall area under the curve [AUC] 0.91 for cardiomyopathies; 0.96 for arrhythmias), outperforming existing tools (4–24% improvement). CardioBoost obtains excellent accuracy (cardiomyopathies 90.2%; arrhythmias 91.9%) for variants classified with >90% confidence, and increases the proportion of variants classified with high confidence more than twofold compared with existing tools. Variants classified as disease-causing are associated with both disease status and clinical severity, including a 21% increased risk (95% confidence interval [CI] 11–29%) of severe adverse outcomes by age 60 in patients with hypertrophic cardiomyopathy. ConclusionsA disease-specific variant classifier outperforms state-of-the-art genome-wide tools for rare missense variants in inherited cardiac conditions (https://www.cardiodb.org/cardioboost/), highlighting broad opportunities for improved pathogenicity prediction through disease specificity.

Influences of machining parameters on tool performance when high-speed ultrasonic vibration cutting titanium alloys

Tool performance is a key factor in evaluating machining processes. To improve machining productivity and part quality, researchers have conducted numerous studies on improving tool performance, such as tool design, coatings, functional micro textures, cooling/lubrication conditions, cutting parameter optimization, and intermittent cutting. Focusing on materials that are difficult to cut (i.e., Ti alloys), this paper explores a high-speed ultrasonic vibration cutting method that combines intermittent cutting, cooling, and lubrication. Through theoretical analysis and experiments on tool wear, cutting force, temperature, etc., the influence of machining parameters on tool performance is investigated. The results show that a large separation effect coupled with good cooling and lubrication conditions is key to improving tool performance. Among these, the feedrate and phase shift resulting from the rotary (spindle) speed are the core machining parameters. On this basis, the choice of machining parameters is summarized to provide a reference for the high-efficient machining of Ti alloys for scholars and engineers. First, cooling and lubrication conditions, such as dry machining and fluids, are determined. The duty cycle is then set from 0.5 to 0.6 via a relatively small feedrate value (i.e. 0.005 mm/r) and a π phase shift. Finally, the cutting speed and depth of cut are chosen according to the requirements of machining efficiency and cost.

Trochoidal milling: investigation of dynamic stability and time domain simulation in an alternative path planning strategy

Trochoidal milling is an alternative path planning strategy with the potential of increasing material removal rate per unit of tool wear and therefore productivity cost while reducing cutting energy and improving tool performance. These characteristics in addition to low radial immersion of the tool make trochoidal milling a desirable tool path in machining difficult-to-cut alloys such as nickel-based superalloys. The objective of this work is to study the dynamic stability of trochoidal milling and investigate the interaction of tool path parameters with stability behavior when machining IN718 superalloy. While there exist a few published works on dynamics of circular milling (an approximated tool path for trochoidal milling), this work addresses the dynamics of the actual trochoidal tool path. First, the chip geometry quantification strategy is explained, then the chatter characteristic equation in trochoidal milling is formulated, and chatter stability lobes are generated. It is shown that unlike a conventional end-milling operation where the geometry of chips remains constant during the cut (resulting in a single chatter diagram representing the stability region), trochoidal milling chatter diagrams evolve in time with the change in geometry (plus cutter entering and exiting angles) of each chip. The limit of the critical depth of cut is compared with conventional end milling and shown that the depth of cut can be increased up to ten times while preserving stability. Finally, the displacement response of the cutting tool is simulated in the time domain for stable and unstable cutting regions; numerical simulation and theoretical results are compared.

РЕЗУЛЬТАТЫ СРАВНИТЕЛЬНОГО ИССЛЕДОВАНИЯ РАБОТОСПОСОБНОСТИ РЕЖУЩИХ ИНСТРУМЕНТОВ ПРИ ОБРАБОТКЕ СПЕЦИАЛИЗИРОВАННЫХ НЕРЖАВЕЮЩИХ СТАЛЕЙ

The paper studies the effect of the tool material on the wear resistance of domestic carbide cutting tools when processing stainless steels. It provides some results of the comparative study of various tool materials operating in similar conditions in order to identify the most efficient ones. The purpose of the work is to identify the most rational tool materials for the given operating conditions of a tool and accumulate a database for recommendation development. The consideration is given to external turning by straight turning tools with mechanically fastened cutting plates. The plates are square and quadrangular (the diameter of the circumscribed circle is 17.5 mm) with and without a central mounting hole, with and without a chip groove. During processing the workpiece diameter has changed from 280 to 60 mm. The cutting speed has been maintained within 50-55 m/min by spindle speed variation. The screw-cutting lathe of model 16K25 is used. The cutter feed is chosen to equal 0.21 mm/rev. of a workpiece based on the surface roughness requirements. The cutting depth is assumed to be 0.5 mm for finishing conditions and 1mm for rough machining conditions. In either case, 0.5 mm is considered the maximum allowable value of wear on the rear face. The cutting tools were compared by their wear resistance period, i.e. according to the operation time of the cutting plates with the proper roughness until the wear of 0.5mm is achieved on the rear face. Machining was interrupted every 15 minutes to measure the amount of wear reached. The wear was measured using a multisensor measuring center (video measuring machine) of Micro Vu Sol 161 model. The test results were duplicated and documented. The conducted study has shown that: wear resistance of tool materials varies significantly; the use of coatings on domestic hard alloy of VK8 grade significantly increases the performance of the cutting plates; the technological method of cutting edge finishing from the front and rear surfaces also significantly increases the working capacity of a tool. To explain the identified results and patterns all three components of the cutting force have been monitored. The analysis of the recording results of cutting force components has shown that their magnitude and correlation significantly depends on the tool material used and material being processed. It has been determined that the role of coating in improving tool performance significantly depends on the operating conditions including the cutting depth. The coating, which showed itself as the most effective (among those considered) at the cutting depth of 0.5 mm, may not be effective at the cutting depth of 1.5 mm and yields to the coating that was second efficient or even third at the depth of 0.5 mm. The conducted experimental studies have allowed to identify the tool materials, whose wear resistance period is the most rational for the stainless steel 09X17H7Yu. These materials include both rational domestic and imported tool materials. Compared tool materials are significantly (two or more times) unequal by the period of their wear resistance. It has been found out that the recommended by the catalogs reference data on cutting mode parameters and an expected durability period for imported tool materials are not confirmed. It has been found out that the recommendations for the choice of domestic tool material and cutting mode parameters are either absent or outdated for this grade of stainless steel. Some technological methods of hardening domestic tool materials that allow to improve tool material performance as good as coating have been revealed. Having studied a number of tool materials, we have identified the most rational for the given operating conditions under finishing and rough machining. Their use allows to carry out machining without changing the cutting edge or plate for an hour or more, which makes them applicable to modern metal cutting high-performance equipment with numerical control and in the structure of automated complexes.

Cutting mechanism and performance of high-speed machining of a titanium alloy using a super-hard textured tool

The study investigates the anti-friction and anti-adhesion effects of micro-textured super-hard polycrystalline diamond (PCD) tools in high-speed machining of a titanium alloy, Ti6Al4V. The experimental results indicate that the friction coefficient can be dramatically reduced by increasing the cutting speed. PCD tools with micro-grooves resulted in less friction during cutting in the absence of lubrication than both un-textured and textured tools with various lubrication condition. It was found that the adhesion area on the rake face of the PCD tool during high-speed cutting can be dramatically reduced by adding micro-grooves near the main cutting edge. It was shown that the maximum width of chip adhesion was reduced by 23.6% on the micro-grooved tool compared to that on the un-textured tool. Furthermore, the results confirmed that TiC can be formed on the surfaces of PCD tools as a bonding layer, which is of significance to revealing anti-friction performance of tool-chip interface. Together, these results show that the directional distribution of the micro-grooves on the tool, the actual tool–chip contact area, the effect of micro-grooves on trapping tiny debris and the TiC bonding layer play important roles in improving tool performance.