An Attempt for Numerical Optimisation of a Micro-Groove Geometry at the Rake Face when Turning Ti6Al4V Alloy with Indexable Inserts

Machining of Ti6Al4V is considered difficult because the material removal rates are relatively small if the tool wear shall be low. In recent years the reduction of process forces as well as tool wear have been investigated by introducing textures (pockets) into the tool surface. To advance the understanding how those textured tools function and to reduce the experimental effort, a smoothed particle hydrodynamics (SPH) model of the orthogonal cutting process with a parametrised tool containing a single pocket on the rake face with variable position and depth is presented. This simulation model is used to enhance the understanding of rake face textures in order to design optimum cutting tools for given process parameters. Using an optimisation algorithm, an optimum texture geometry is determined numerically and is then experimentally validated, followed by a discussion, why process force reductions are lower than predicted.