Tool wear analysis of turning Ti-6Al-4V under dry, wet and cryogenic conditions

Economy of a manufacturing system is symbolic of its wholesome efficiency. Machining of difficult-to-cut titanium alloys has persistently presented a challenge due to its high temperature strength, low thermal conductivity and poor modulus of elasticity. In addition to the loss of economy owing to accelerated tool wear, the machine downtime also degrades manufacturing system efficiency. In the present research, effects of machining parameters and cooling systems were analyzed in terms of tool wear, which is a key productivity index, during turning of Ti-6Al-4V. Machining environments including wet and cryogenic conditions as well as dry machining was employed for experimentation. It was seen that tool wear can significantly be reduced by use of correct machining parameters in combination with appropriate cooling system. Cryogenic condition was found to cause 23% and 12% lesser wear than corresponding dry and wet machining at 60 m/min. SEM imagery identified adhesion and diffusion dissolution as the main wear inducing phenomena. ANOVA results identified cutting speed as the most substantial factor affecting tool wear with contribution ratio of 52.96%. Tool chip contact analysis depicted the lesser contact area under the usage of coolant reducing tool wear.