Effects of the Tool Microgeometry on Thermo-Mechanical Loads for Ti-6Al-4V Finishing Cutting Operations

Achieving a high-quality surface while minimizing the adverse effects associated with machining operations, particularly in finishing processes, is a major challenge in aerospace component manufacturing. To overcome the limitations of conventional numerical simulations of cutting operations, which involve chip formation and complex contact management, this paper proposes a simplified approach to model the thermal loading generated during cutting using a chipless method. After analytically determining the effort-based thermal sources and validating the chipless model, the influence of tool microgeometry on thermo-mechanical loading is investigated emphasizing this parameter as an important factor for finishing cutting operations.