Internal cooling system effects to heat transfer and tool wear in turning operations of titanium alloys Ti6Al4V

Internal cooling systems are essential for turning operations to improve the efficiency and quality of the machining process. In this paper, application of the virtual machining system is developed to analyze the effects of internal cooling systems on heat transfer and tool wear in turning operations of titanium alloys Ti6Al4V. The cutting forces as well as cutting temperature along machining paths are simulated in the virtual machining system to predict and analyze the effects of internal cooling system to the heat transfer and tool wear during turning operations. The coolant flow inside the internal cooling channels of a rotating cutting tool is simulated using computational fluid dynamics. Next, utilizing the modified Johnson–Cook model, the cutting temperature during turning operations is determined. The finite element method is employed to predict tool wear by applying the Takeyama–Murata analytical method. To validate the study, experimental works are implemented using turning machine tool. The cutting settings during experimental works are feed rate of 0.3 mm/rev, depth of cut of 2 mm, and cutting speed of 75 m/min. Thus, using the proposed virtual machining system, the performance of internal cooling system can be enhanced to increase cutting tool life and surface quality of machined parts in turning operations.