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Micro-grinding of micro-groove array on tool rake surface for dry cutting of titanium alloy

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Abstract

A micro-grinding approach is proposed to fabricate micro-groove array on tool rake surface. These micro-grooves were used to rapidly dissipate cutting chips and heat from cutting zone for eco-cutting of titanium alloy without any coolant. This tool is called micro-grooved tool. The objective is to replace chemical and high-energy-beam etching approaches because they have not yet been able to control micron-scale groove shape accuracy. In this study, a superhard diamond wheel V-tip was employed to perform a micro-grinding through a traverse grinding. After micro-grinding, these micro-grooves were characterized by the mean depth of 155.1 μm, the mean form error PV of 7.8 μm and the mean tip radius of 45.6 µm. Firstly, traditional plate tool, orthogonal micro-grooved tool and diagonal micro-grooved tool were employed to perform a dry turning of titanium alloy, respectively; then, tool wear, surface roughness, chip topography and shear angle were investigated. It is shown that the sharpened diamond wheel V-tip is valid to grinding micro-groove array on tool rake surface without any burrs. Furthermore, the micro-grooved tools may reduce the cutting sparks, tool wear, 3D chip size and chip saw-tooth size compared to traditional plate tool. The diagonal micro-grooved tool may decrease tool wear by 6.7% and surface roughness by 37.3% and increase shear angle by 24.3% against orthogonal micro-grooved tool, respectively. This is because the diagonal micro-grooving direction is identical to the cutting chip flowing on tool rake surface. It is confirmed that the diagonal micro-grooved tool is applicable to a stable dry cutting of titanium alloy.

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Authors and Affiliations

  1. School of Mechanical & Automotive Engineering, South China University of Technology, Guangzhou, 510640, China

    Jin Xie, Min-Jian Luo, Xu-Ran Liu & Ting-Wu Tan

  2. Jiangmen Technician College, Jiangmen, 529030, Guangdong, China

    Jian-Lin He

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  1. Jin Xie
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  2. Min-Jian Luo
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  4. Xu-Ran Liu
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Correspondence to Jin Xie.

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Xie, J., Luo, MJ., He, JL. et al. Micro-grinding of micro-groove array on tool rake surface for dry cutting of titanium alloy. Int. J. Precis. Eng. Manuf. 13, 1845–1852 (2012). https://doi.org/10.1007/s12541-012-0242-9

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  • DOI: https://doi.org/10.1007/s12541-012-0242-9

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