Process behaviour of micro-textured CVD diamond thick film cutting tools during turning of Ti-6Al-4V

Currently, an efficient machining of high-performance materials, such as titanium alloy Ti-6Al-4V, represents a challenge in manufacturing. For the reduction of high cutting temperatures, micro-textured CVD diamond thick film cutting tools establish new potentials regarding the process productivity. The application of micro-textures allows a reduced contact area between chip and tool in order to decrease the generation of heat. Furthermore, a direct application of lubricant into the cutting zone is possible. The present study investigates the influence of micro-textured CVD diamond thick film cutting tools on the resulting process forces, chip formation as well as maximum cutting volumes during turning process. Part of the investigations was a variation of micro-texture trajectory with micro-textures parallel to the major cutting edge, perpendicular to the bisector of corner angle ϵ and curved along the cutting edge. The analyses showed that both positive and negative effects occur using micro-textures. The forces can be reduced by 14 % whereas the use of micro-textures leads to higher feed forces Ff by 21 % as well as an additional notch effect in the micro-texture bottom.