Dual textured carbide tools for dry machining of titanium alloys

During dry machining of titanium alloys, severe friction exists at the tool-chip interface, which causes excessive heat generation and tool wear. To limit the tool-chip interface friction and to change tribological characteristics, texturing of the tool rake surface is one of the feasible solutions. In this study, innovative dual texture geometries consisting of grooves in the sticking and dimples in the sliding regions over the tool-chip contact area were fabricated. The other combinations included grooves or dimples spread over the entire tool-chip interface and the non-textured tools. Turning experiments showed that the dual textured tools reduced cutting and thrust forces by 31.2% and 16.2%, respectively, over non-textured tools. Surface morphology and elemental dispersive spectroscopy of dual textured tools rake surface had lower workpiece adhesion and less built-up-edge formation due to wear debris entrapment inside the textures. Dual textured tools produced almost continuous chips with very thin segmentation at low feeds compared with non-textured tools which produced highly segmented chips. The analytical model captured the effect of textures on the tool surface in the same way as the reduced contact area tools, and it was in good agreement with corresponding experimental cutting forces. •Innovative dual texture geometries consisting of grooves and dimples are fabricated on tool rake surface.•Machining experiments were performed using various cutting tools.•Cutting and thrust forces were measured and coefficient of friction was calculated.•Tool wear and chip morphology were analyzed.•An analytical model is proposed relating cutting force and contact area of the textured tool.