This work focuses on the 3D numerical investigation of machinability criteria using textured tools for the dry machining of titanium grade 2. For the development of the 3D finite element model, DEFORM-3D (version 10.1) software was used. Dimple patterns were created nearer to the cutting edge region on the rake face of carbide inserts so as to predict their effect and investigate the machinability criteria. Comparison of dimple-textured tool was being made with a conventional tool based on the cutting forces ([Formula: see text], [Formula: see text] and [Formula: see text], cutting temperature, tool wear, effective stress and effective strain. The numerical study revealed that the dimple-patterned tool improved the machinability of titanium grade 2. The cutting forces (tangential cutting force, feed force and radial force) reduced while machining with a dimple-patterned tool as compared to the conventional nontextured tool. There was an enhancement of tool life and a decrease in effective stress and effective strain while dry turning grade-2 titanium alloy using the textured tool.

Owing to minimum quantity or no use of toxic coolants, the dry machining technique has been evidenced to be a versatile sustainable method. However, during dry machining of ductile alloys, the severe tool wear and metal adhesion on the rake face of the cutting tool has been a matter of great concern. In the present work, an attempt has been made to assess the improvement in the tribological conditions in dry cutting by providing surface texturing on the rake face of High-Speed Steel (HSS) cutting tool. Dimples were produced on the rake surface of the HSS tool using pulsed Nd: YAG Laser and dry turning of pure aluminium is performed using the textured tool based on Taguchi’s L9 orthogonal array (OA) experimental design. The dry cutting of pure aluminium was also performed using the conventional/un-textured tool and the obtained results are used for comparison purpose. Improved turning performance in terms of material removal rate and surface roughness is found from the conformation tests using optimum process parameter determined by the Taguchi analysis. The ANOVA results suggests the effectiveness of using the textured tools during dry machining is significantly affected by feed and speed.

This study has been carried out to understand and reveal the efficacy of using surface-textured tools in the dry turning of Ti grade-23 alloys. The textures have been fabricated nearer to the primary cutting edge (in the rake face) and the secondary cutting edge (in the flank face) of the tool. The method used for texture fabrication is a nonconventional machining technique, Wire Electro-discharge Machining (WEDM). Micro-grooves/channels have been fabricated in the tools (rake face and flank face). The study also aimed to reveal the influence of texture pattern as well as its position on the cutting edges. The rake face-textured tools had four varieties: vertically textured (VT-R), diagonally textured (DT-R), horizontally textured (HT-R) and cross-textured (CT-R). On the other hand, the flank face had three varieties: cross-textured (CT-F), horizontally textured (HT-F) and vertically textured (VT-F). The cutting performance was measured and compared among the aforementioned different textured tools and nontextured (NT) ones in terms of the forces ([Formula: see text], [Formula: see text] and [Formula: see text]), temperature, tool wear and chip morphology. The study revealed that the textured tools performed better and the VT-R tool performed the best followed by the DT-R and VT-F tools as compared to NT ones for the dry turning of Ti grade-23 alloys.

In this study, through numerical simulation, an effort has been made to acknowledge the efficiency of machining Titanium grade 23 under vibration assistance with textured cutting tools. Dry turning experiments with commercially available carbide inserts without texturing were carried out without vibration assistance. Cutting forces ([Formula: see text], [Formula: see text], [Formula: see text]) were observed during experimentation, which were further validated using DEFORM 3D. The forces were validated using DEFORM 3D. Closer to the cutting edge, dimple type 1, dimple type 2, horizontal, and vertical patterns were made on cutting inserts using SOLIDWORKS software. A numerical model based on experimentation was developed employing DEFORM 3D software for conventional and vibration-assisted turning. Cutting forces ([Formula: see text], [Formula: see text], [Formula: see text]), cutting temperature, tool wear, and the mechanism of chip formation were also explored through FEM investigation. Micro-textured inserts were found to be enhancing machinability. Machining with vibration assistance also improved machinability. The study found that textured tools improved machinability in conventional and vibration-assisted machining modes. The effect of textured tools on machinability improved with vibration-assisted machining. The numerical analysis revealed that dimple type 1 and vertical grooved tool improved the machinability of Titanium grade 23.