Tool Wear Behaviors of CVD-Coated Carbide Inserts During Dry Machining of Titanium Grade-5(Ti-6Al-4V) Materials

Abstract

Flank wear is the most normally observed and inevitable phenomenon in metal cutting which is also the main source of commercial loss resulting due to material loss and machine down time. In this research work, the tool wear behavior and surface roughness of the titanium alloy have been identified. The machining operation like turning was conducted on titanium grade-5 alloy using the CVD-coated carbide inserts under the dry condition at the moderate speed of the lathe machine. The surface quality of the material was found with respect to machining parameters like speed, feed and depth of cut, and also observed that the tool flank wear is one of the major contributing factors to get error in the geometry, and there will be thermal losses or low thermal expansion in the work piece. The different types of tool wear do not cause the geometry of tool directly but can get very high cutting forces slowly or gradually. In the machining processes, it provides the information of geometric errors and surface roughness, which are associated with specimen. Using the different machining parameters at different levels of experimental test to find out the tool flank wear of CVD inserts by one of the techniques called tool wear monitoring. The carbide tool (CNMG120412) is used for the experimental work. Several experiments are carried out and the results are plotted in the form of graphs. These graphs show the variation of cutting forces and flank wear with respect to cutting speed, and various conclusions are drawn from these graphs. Tool condition monitoring tests are conducted to observe the tool flank wear of the carbide tool.