Effect of tool microstructure on machining of titanium alloy TC21 based on simulation and experiment

Titanium alloys have high corrosion resistance and specific strength, leading to a wide range of uses in a variety of industrial fields. However, machining performance is often very poor, causing serious difficulty during the cutting process. In particular, high cutting temperature and high chemical activity of titanium alloys during the cutting process lead to rapid tool wear. Within this research, specific tool microstructures cut onto the tool rake surface is explored to improve the cutting performance of titanium alloy TC21. In order to isolate the influence of particular tool microstructures on the cutting performance of titanium alloy TC21, a 3D orthogonal finite element model (OFEM) is utilized to simulate the cutting process of TC21 alloy. The impact of tool microstructure on chip formation, cutting force and temperature is thoroughly analyzed through turning simulations and experiments on titanium alloy TC21. Finally, a comprehensive comparison of cutting behaviors between textured and untextured tools during the cutting of titanium alloy TC21 was carried out. Cutting simulations indicate that tool microstructure can improve the cutting properties, reducing cutting temperature and cutting force. Research results confirm that chip serration and tool wear noticeably decreased, indicating tool texture can significantly improve cutting performance of titanium alloy TC21.