Effect of grooving textured tool on the titanium chip morphology

The observation of segmented chips in titanium alloy machining is a common phenomenon that leads to undesirable effects on tool life and characteristics of the machined surface. During grooving operation in the turning process, the contact area of the tool and workpiece is high, and the cross-section of the tool shank is small, which signifies the necessity of machinability improvement. The texture patterns have been recently used, which reduced the friction (force) and temperature of pair surfaces. Hence, in this study, linear and hole texture designs are considered on the rake face to investigate the effect of tool surface texture on chip morphology of TiAl6V4 titanium alloy during the grooving operations. The results showed that using texture on the tool's rake face at a 94 m/min cutting speed reduced the cutting force up to 38% compared to the simple tool. Also, the use of texture on the tool's rake face reduced the thickness of the chip up to 20% compared to the simple tool. Also, the linear texture design resulted in the lowest value of G and the highest value of fc, which means the most dynamic stability of the machining condition.