Towards understanding the wear mechanisms of turning with FreeTurn

For many years, tool wear has been a critical issue with respect to productivity, cost, and part quality, particularly for superalloy machining. The underlying wear mechanisms of a new turning tool, FreeTurn, is revealed in this paper towards its potential for a more sustainable way of metal cutting. It is a specially designed turning tool that is held by the tool spindle and has a working plane perpendicular to the centreline of the tool spindle, making it rotatable on its working plane. Owing to the unique feature of FreeTurn compared with conventional turning tools, the focus of this study is on the effect of dynamic tool–workpiece engagement on tool wear. The tool path strategy is first set to achieve a cylindrical surface in longitudinal turning with a rotatable FreeTurn tool. Series of experiments with different tool path strategies are performed on a turn–milling machine, using Inconel 718 as an example of workpiece material. The results indicate that the coupling effect between notch and flank wear is the decisive factor of tool wear in free turning with respect to its rotation and feeding directions. While the tool wear can be significantly reduced if the tool feeds with increasing cutting edge angle, the tool will soon be worn out if it feeds with decreasing cutting edge angle. Tool rotation in free turning plays a key role in reducing adhesion on the cutting tool and increasing the tool rotation speed can further improve this effect. Additionally, a more sustainable solution that uses both sides of the cutting edge becomes possible with FreeTurn as well, improving the tool utilisation. The results demonstrate considerable guiding significance for exploring the potential of this new turning tool towards a longer tool life. •The wear mechanisms of a newly–developed turning tool (FreeTurn) is revealed.•Tool wear can be significantly reduced in dynamic turning under the condition of increasing cutting edge angle.•As the main wear mechanism, adhesion can be mitigated by dynamic tool–workpiece contact.•Increasing tool utilisation by using both sides of the cutting edge becomes possible in free turning.