Experimental analysis and characterisation of chip segmentation in dry machining of Ti-6Al-4V alloy using inserts with hybrid textures.

• Dry machining of Ti-6Al-4V alloy using novel duel-textured inserts reduces the cutting forces and friction experienced. • Machining with textured inserts can produce chips with significant variations in segment size, shape, and geometry. • Quantitative analysis revealed that the textured inserts produce chips with high shear angle and low segment strain. • The microstructure in the chip produced with textured inserts show differences in strain hardening. • An increase in cutting velocity beyond a critical value could undermine the performance of textured tools. Cutting tool surface texturing is emerging as an eco-friendly alternative to improve the tribological aspects and enhance machining performance. Despite several studies on the merits of textured cutting tools, limited information is available on their effect on chip segmentation. This study presents a quantitative analysis of the chip segmentation characteristics in dry machining of Ti-6Al-4V alloy using duel-textured carbide inserts. The optical and scanning electron microscopy analyses were performed to characterise the chip morphology. The effects of rake surface textures on segment width, shear angle, and chip thickness ratio were assessed and compared with the conventional inserts. In addition, the influence of surface textures on the microstructure of chip roots and the surface roughness of the workpiece was investigated. It appears that the textures on the rake face help reduce the spacing between the segments and the extent of fracture along the shear plane, ultimately reducing the segment strain and surface roughness. Therefore, this study facilitates the understanding of chip morphology and its evolution in turning operation using textured inserts and brings its industrial implementation a step closer. [ABSTRACT FROM AUTHOR]