Performance of laser processed carbide tools for machining of Ti6Al4V alloys: A combined study on experimental and finite element analysis.

Abstract Tool surface modification strategies are expected to achieve energy efficient dry cutting pertaining tribological advantages of textured surfaces. Current work focuses on both experimental and finite element based approaches to understand the effect of textured and coated textured tools on machining performance of Ti6Al4V alloy. Novel chevron textured tools were fabricated using nanosecond fiber laser and further coated with PVD-TiAlN coating. 2D FE simulation studies for turning with uncoated textured and TiAlN coated-textured tools were performed and compared with plain and coated-plain tools. The effectiveness of the textured tools is evaluated in terms of cutting forces, average friction coefficient, tool-chip contact length, chip disentangling behavior, and shear stresses between coating-substrate adhesions. Results confirm that the coated textured tool is helpful in machining performance improvement of Ti6Al4V alloys even at comparatively higher cutting speeds and feed. The concept of interface multipoint micro-cutting (IMP-μC) at varying machining speeds was observed from FE simulations and verified from experimental results. Highlights • Plain and chevron textured tools were used with uncoated and TiAlN coatings for turning of Ti6Al4V. • Cutting tests were conducted for forces, apparent friction, chip contact length, curling and disentangling behavior. • Experimental results are validated for FE simulations and compared for the analysis. • Texture induced derivative cutting phenomenon is explained with FE simulations and experimentally validated. • Reduction in maximum shear stresses at flank for textured tools reduced delamination of coatings. [ABSTRACT FROM AUTHOR]