Effects of rake surface texture geometries on the performance of single-point cutting tools in hard turning of titanium alloy

Texturing of cutting tool surfaces is emerging as one of the viable solutions to enhance tribological characteristics during machining. Apart from the cutting regime used, the effectiveness of textured tools also depends on the texture geometries. Accordingly, the present study investigates the effect of four different micro-textures on the rake surface of cutting tool inserts in hard turning of Ti-6Al-4V alloys. It specifically addresses the effect of micro-textures on the tool-chip contact length and chip morphology. This study also compares the experimental tool-chip contact length with a new model proposed for inserts with textures. The effect of different insert texture geometries on chip morphology has been investigated by characterizing the chips produced during the cutting. Further, the effects of texture geometries on the parameters like chip compression ratio and shear angle were examined. A detailed analysis has beeen carried out using inserts with and without micro textures to understand their effect on the mechanics of machining. Quantitative predictions were made on the effectiveness of the texture geometry in reducing the cutting forces and friction during machining.