Effect of cutting tool geometry on tool wear and tool temperature during Ti-6Al-4V machining

Titanium and its alloys have been perceived as difficult to machine material due to its several peculiar properties such as low thermal conductivity and high chemical reactivity. Rapid tool wear has been observed as the main problem in machining of titanium alloys which prevails due to high cutting zone temperature localised in the vicinity of the cutting edge and enhanced chemical reactivity of titanium at tool operating temperature. The present investigation focuses on the effect of different insert geometries namely rhomboid, square and round, on the flank wear during titanium alloy machining under dry cutting conditions. A substantial reduction in tool flank wear was observed for the round insert. Also cutting temperature for different insert geometries has been estimated by Finite element method. The results obtained provide a fundamental understanding how does the tool geometry affect the tool temperature during machining