Numerical Investigation of the Derivative Cutting Effect of Micro-Textured Tools in Dry Cutting of Ti6Al4V

In this study, FEM simulation of titanium alloy machining with micro-textured tool using Thirdwave AdvantEdge. Micro-scale textures on the rake face of the cutting tool is a single linear groove parallel to the cutting edge. Viewing simulation results ,derivative cutting did occur under the cutting parameters in this study. The tool-chip contact length decreases due to the existence of the micro-textures. Shear angle increases which indicates smaller deformation of the cutting layer and thus smaller cutting forces and cutting temperature. However, the derivative cutting effect increases the variations of the cutting forces. Therefore, strength of the cutting tool must be taken into consideration during the designation of the micro-textured cutting tool.

A Study on New Surface Textured Tools for Inhibition of Derivative Cutting

Derivative cutting is a texture-edge cutting of chip bottom side, which happens all the time in machining with textured tools. Two new types of textured tools are developed and fabricated: a micro-textured tool with chamfered texture edge (CTE) tool and a multiscale textured (MSTT) tool with the texture surface below the rake face. The effectiveness of the tools on inhibiting derivative cutting is investigated at different cutting velocities. For the CTE tool, the inhibiting effect is more pronounced with the increase in the chamfer angle, but the severe rake face wear eventually leads to the occurrence of derivative cutting. Compared with the CTE tool, the multiscale textures of the MSTT tool provide more sustainable effectiveness in inhibiting derivative cutting. The inhibition mechanisms of the two types of textured tools are discussed.

A Simulation Study on the Effect of Micro-Textured Tools during Orthogonal Cutting of Titanium Alloy Ti-6Al-4V

The cutting force, cutting temperature and mechanisms are studied by Finite Element Method during the orthogonal metal cutting of Ti-6Al-4V with micro-textured cutting tools. The relation between the texture’s antifriction effect and the parameter of the textures is analyzed. The Derivative-Cutting phenomenon is found when cutting Ti-6Al-4V using textured tools. The mechanisms about how the micro-textured tools change the frictional behavior in the chip-tool interface are explained using Derivative-Cutting characteristic. The antifriction performance of micro-textured cutting tools in the metal cutting process is discussed. The cutting force and cutting temperature is decreased effectively in the cutting simulation with the micro-textured tools manufactured in reasonable parameters.