Accepted Manuscript

Performance of laser processed carbide tools for machining of Ti6Al4V alloys: A

combined study on experimental and finite element analysis

Sarvesh Kumar Mishra, Sudarsan Ghosh, Sivanandam Aravindan

PII: S0141-6359(18)30315-5
DOI: https://doi.org/10.1016/j.precisioneng.2019.01.006
Reference: PRE 6898

To appear in: Precision Engineering

Received Date: 19 May 2018

Revised Date: 15 August 2018
Accepted Date: 21 January 2019

Please cite this article as: Mishra SK, Ghosh S, Aravindan S, Performance of laser processed carbide
tools for machining of Ti6Al4V alloys: A combined study on experimental and finite element analysis,
Precision Engineering (2019), doi: https://doi.org/10.1016/j.precisioneng.2019.01.006.

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 ACCEPTED MANUSCRIPT

Performance of laser processed carbide tools for machining of Ti6Al4V alloys: A combined
study on experimental and finite element analysis

Sarvesh Kumar Mishra, Sudarsan Ghosh, Sivanandam Aravindan*

Department of Mechanical Engineering, Indian Institute of Technology-Delhi, Hauz Khas

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New Delhi, India
*Corresponding Author (E-mail: aravindan@mech.iitd.ac.in)
Abstract

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Tool surface modification strategies are expected to achieve energy efficient dry cutting

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pertaining tribological advantages of textured surfaces. Current work focuses on both
experimental and finite element based approaches to understand the effect of textured and coated
textured tools on machining performance of Ti6Al4V alloy. Novel chevron textured tools were

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fabricated using nanosecond fiber laser and further coated with PVD-TiAlN coating. 2D FE
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simulation studies for turning with uncoated textured and TiAlN coated-textured tools were
performed and compared with plain and coated-plain tools. The effectiveness of the textured
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tools is evaluated in terms of cutting forces, average friction coefficient, tool-chip contact length,
chip disentangling behavior and shear stresses between coating-substrate adhesions. Results
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confirm that the coated textured tool is helpful in machining performance improvement of
Ti6Al4V alloys even at comparatively higher cutting speeds and feed. The concept of interface
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multipoint micro-cutting (IMP-µC) at varying machining speeds was observed from FE

simulations and verified from experimental results.
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Keywords Textured tools; 2D FEM; Ti6Al4V machining; Laser texturing; TiAlN coating.

1. Introduction
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Ti6Al4V has been the workhorse for the aerospace, automotive, biomedical, petroleum and
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marine industries due to its lower density, high strength to weight ratio and fracture toughness.
However, it also has higher temperature strength compared to steels and aluminum alloys, high
strain hardening, low thermal conductivity and high chemical reactivity [1]. These factors result
in poor machinability of Ti6Al4V due to high tool wear, high interface friction and chip
adhesion. Due to low thermal conductivity and high specific heat, a significant portion (up to
80%) of heat generated during machining remains confined over the tool-chip interface [2]. This
causes high temperature in the cutting zone which in turn significantly reduces the tool life

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during machining of titanium alloys. During titanium machining, high contact load on chip-tool
interface generates high interface friction. It is desirable to decrease the heat generated at the
interface which lowers the friction and the adhesion of chip on the tool rake face during
machining of Ti6Al4V.
Recent developments in tribological studies have been a motivation towards improved process

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and tooling design for machining difficult-to-machine materials. Reduced friction in tool-chip
tribopairs has been achieved by application of various cutting fluids and coatings. But due to

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strict environmental regulations, high recycling cost of cutting fluids and occupational health
risks, dry or near dry machining is becoming the order of the day. Various sustainable machining

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techniques have been proposed in the past for machining of steels, titanium and Inconel alloys.
The majority of the environmentally benign techniques are coolant and lubricant based, e.g.,

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minimum/small quantity lubrication (MQL/SQL), minimum quantity cooling and lubrication
(MQCL), cryogenic cooling and Nano-MQL [1]. Recently, tool based sustainable techniques
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have been used for dry cutting of different engineering alloys. Tool based technique applies
surface modification on cutting tools as a method of reducing friction by suitably texturing the
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tool rake and the flank surfaces. Newer research findings have been oriented towards application
of surface textured tools as one of the possible sustainable machining techniques. Textured tools
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assist in reducing friction, adhesion, and improving wear resistance due to various underlying
mechanisms in tool-chip interaction zone. The mechanisms mainly responsible for improved
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performance are reduced contact length [3,4], the formation of micro-pool reservoir [5], the
formation of thin shear film due to solid lubricants [6–9], and built up edge stabilization [10].
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Various methods have been used to create different types of textures at rake and flank surfaces of
the tool. The most widely used methods for generation of textures on tools are laser surface
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texturing [5–7,9], micro EDM [11–13], and focused ion beam (FIB) machining [14,15]. Focused
ion can be used to impart high surface finish to textures on cemented carbides compared to laser
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beam or any other method of micromachining[16]. But the low cost of fabrication and high
material removal rate make laser micromachining as the most common method of texture
fabrication.

In literature, a considerable amount of work on the effectiveness of textured tools in machining

applications can be found. Laser textured micro/nano tools have also been used to machine
A5052 alloy under MQL environment [17]. Experimental results were compared to different

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types of microgrooved textures and reduced forces, reduced chip-tool contact length and lower
chip adhesion had been reported. Photolithography assisted texture patterns of different shapes
(perpendicular and parallel grooves, pits and dots) were fabricated on nickel-coated cutting tool
surface [18]. The textured tools were further DLC coated and used for machining aluminum
A6061-T6 alloy at varying speed and wet condition. The results suggested that the parallel and

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dot type textures were more effective in reducing friction forces, adhesion area and coefficient of
friction. Xing et al. [19] studied the effect of microscale and nanoscale textures fabricated on

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ceramic tools burnished with MoS2 for machining of hardened steels. Micro-scaled linear and
wavy grooves were compared with nano-scaled textured for cutting forces, temperature, friction,

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surface roughness and tool wear. Cutting temperature was reduced in all the textured tools
compared to plain tools due to the formation of low shear strength film and reduced contact area.

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Lei et al. [5] reported the effect of micro-pool lubricated tools for steel machining and found that
the textured tool performed better than plain tools. In the same study, FE simulations also
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confirmed that the texturing had not induced any negative effect on the strength of the tool.
Linear and zig-zag texture array with a constant depth, varying diameter and spacing (area ratio)
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on WC-Co tools were used for machining steel with emulsion type fluid [20]. Maximum depth of
crater, cutting forces and friction coefficient were compared for dry, paste type lubricant and wet
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condition. Major mechanisms for improved performance were the micro-reservoir formation and
wear debris entrapment. Least crater depth, cutting forces and friction coefficient were observed
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for DT-05 (linear textures with 68.3% area density) in both dry and wet conditions.

Various studies have been conducted for machining of low strength steel and aluminum alloys,
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but there still remains a dearth of investigation for the performance of textured tools in
machining of difficult to cut materials. Rathod et al. [21] investigated micro-grooved tools for
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machining Ti6Al4V alloys, and they have experimentally optimized the texture parameters for
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cutting tools. Square (crossed micro grooved) textures were reported to be the most effective in
reducing friction, cutting forces and chip adhesion. Yang et al. [22] have studied the effect of
micro-grooved tools in machining of titanium alloy under MQL environment at constant cutting
speed and feed. Their study also revealed a decrease in friction and cutting forces for optimized
micro grooved parameters. Apart from the plain cutting tool inserts, microgrooves were also
fabricated on complex drill bit geometry for drilling of titanium alloy with lube dipped tools
[23]. The textures were fabricated at varying coverage area of 10% and 20%. The overlap

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between the successive textures was considered to have a positive impact on the machining
performance. Only 33% of textured drills failed while drilling 60 holes compared to 100% with
non-textured drills.

Most of the studies have focused on machining with textured tools and soft coatings of solid

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lubricants. Generally, MoS2, WS2, and CaF2 based solid lubricants are used for impregnating
textured tools by burnishing or coating techniques. With solid lubricants, improved machining
and tribological performance are achieved but its effectiveness over longer cutting time remains

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a debatable topic. Also, these coatings can sustain the temperature only up to 5000C, beyond
which there exists a tendency of solid lubricants to get oxidized and thereby causing oxidation

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wear [24]. Limited studies have been conducted for textured tools coated with hard ceramic
coatings. Zhang et al. [25] studied the effect of TiAlN coating on microgroove textured tools

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during machining of AISI1045 alloy under flood and starved lubrication. Secondary lubrication
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(micro-pool reservoir) effect and debris entrapment mechanism due to texturing were reported to
be less effective under high-speed conditions. Experiments with microgrooved tools coated with
TiN and TiAlN have been conducted under semi-solid lubricated (MoS2 dispersed in oil)
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environment [13]. Improved performance regarding reduced cutting forces (10-20%) and
decreased flank wear for coated tools was observed.
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The experimental work conducted with textured tools justifies its application in machining.
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Recently, finite element method based approaches have been gaining interest to evaluate
different types of textured tools for machining applications. The primary challenge of conducting
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experimental studies with the textured tool is the time, accuracy of manufacturing micro-
features, and cost involved in fabricating the tools with different feature shape and texture
parameters for selecting a suitable textured tool for machining. FE simulations have been carried
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out for AISI1045 machining with varying microgroove parameters [26]. It was concluded from
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the simulation results that the optimized texture parameters could effectively reduce cutting
forces and friction. Dong et al. 2015 [27] used FE simulations to study the orientation of
different microgroove textured tools used for machining of AISI52100 steel. Up to 28%
reduction in coefficient of friction was reported, and parallel textured grooves to cutting edge
were found to reduce the forces and friction coefficient effectively. Simulation studies have also
been conducted to evaluate the effectiveness of textured tools for machining of Ti6Al4V with

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micro-hole textures [28]. Finite element studies were also found to be effective in optimizing the
texture parameters (pitch, depth, and diameter of holes /width of the channel).

From the available literature, it is observed that textured tools have been widely used with solid
lubricants, but comparatively hard ceramic coatings on textured tools are still less investigated.

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Most of the work has been focused only on microgrooved (channel textured), micro pits, micro
holes, and cross-hatched textures. The previous studies have proved texture effectiveness in
machining, and it further paves the need to evaluate new texture shapes of different geometry,

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coatings, and varying machining conditions. The motivation of present work is to assess
machining of Ti6Al4V with textured uncoated and textured TiAlN coated tools with the help of

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FE simulations. A combined experimental and FE simulation study is conducted to understand
the underlying effects of texturing and subsequent coating on cutting tool performance. The

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novelty of surface architecture of chevron textures for hard coatings is experimentally tested for
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its machining performance and validated with FE simulations. The focus of the study is to
accelerate the application of hard ceramic coated and textured tools for machining difficult to cut
aerospace alloys.
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2. Finite element simulations

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AdvantEdge® finite element (FE) software package (Version: 7.3, Third Wave Systems, USA)
has been used to simulate the machining of Ti6Al4V using plain and textured carbide inserts. FE
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studies have been performed after initial machining trials for different texture shapes.
AdvantEdge® is a Lagrangian explicit dynamic code written to perform finite element based
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machining simulations. Adaptive meshing with Lagrangian FE formulation was used and applied
for continuous meshing and remeshing of chip and workpiece. All simulations were run in
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standard mode with chip breakage enabled. Default 4-node, 12 degrees of freedom tetrahedral
finite elements were used to model the tool and workpiece materials. A maximum number of
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nodes generated was 24000 with fine mesh grading. The present FE simulations involve
performance study of plain and textured carbide inserts under the dry condition for machining of
Ti6Al4V alloy.

2.1 Workpiece material model

Simulation results and its validity depends heavily on the selected material model, input
properties, frictional, and boundary conditions. FE simulations have been used as a powerful tool

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to assess different constitutive material models for machining studies. Selection of accurate
constitutive model is necessary for simulating the desired output. User-defined temperature
dependent Johnson-Cook model (modified J-C model) has been selected for the present study as
this model is capable of describing material behavior at large machining strains and strain rates.
Johnson-Cook equation relating equivalent stress (
) with plastic strain () and strain rates () is

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given in Equation 1.
  

=  +
.   1 + .    1 −    (1)

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Table 1 Johnson-Cook parameters for Ti6Al4V alloy [29]

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J-C parameters Value
Yield strength A 782.7MPa
Hardening modulus B 498.4 MPa

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Hardening coefficient n 0.28
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Strain rate sensitivity coefficient C 0.028
Reference plastic strain rate  1 sec-1
Room temperature T0 200C
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Melting temperature Tm 16600C

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The values of constitutive model parameters for Ti6Al4V are given in Table 1. Thermal
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softening coefficient (m) is kept as unity in this case. Mechanical properties of Ti6Al4V,
WC/Co, and TiAlN coating material are presented in Table 2. For better thermal softening
assessment, temperature-dependent thermal conductivity, K(T) and specific heat, Cp(T) are given
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as inputs during titanium machining similar to author’s previous work [30,31].

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Table 2 Mechanical and thermal input parameters for workpiece, tool, and coating materials
Properties Ti6Al4V WC/Co TiAlN
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Density (Kg/m3) 4430 14,900 4700

0 -1
The coefficient of thermal expansion ( C ) 9.1E-6 4.8E-6 As of tool material
Young’s Modulus (Pa) 1.13*E11 6.45*E11 3.1*E11
Poisson ratio 0.34 0.24 0.22
-1 -1
Thermal conductivity (W.m .C ) K(T) 91 16
Specific heat (J.kg-1.C-1) Cp (T) 206 779

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The workpiece is modeled with length 15 mm and height 3 mm for 2D simulations. To select
element size for the workpiece, mesh convergence test is run to maintain a balance between
computational time and simulation accuracy. Based on the mesh convergence test, minimum
element size 0.01 mm is selected. Simulations have been run for a cutting length 10 mm in all

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conditions. Fig. 1 shows simulation set up and enlarged view of textured tool’s interaction with
modeled workpiece. The workpiece is given a constant velocity corresponding to cutting speed

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to provide relative motion for cutting.

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Fig. 1. Simulation set up with meshed tool and workpiece and enlarged view of tool-workpiece
interaction with finer mesh over tool rake face
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2.2 Tool modeling and TiAlN coating parameters

Tungsten carbide (WC/Co) tools with geometry CNMA120408 are selected for this study. Plain
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and textured tools are modeled in AdvantEdge® tool editor environment with the parameters
given in Table 3. Tool material properties for WC/Co is taken from [32] as mentioned in Table
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2. Tool edge radius is 5 µm for simulations with uncoated (plain and textured) tools. 2D cross-
sectional dimensions have been used to model the textured tool as shown in Fig. 2(a). Tool and
workpiece are meshed with meshing parameters given in Table 4, and fine meshing is provided
at the rake face. TiAlN coating of thickness 4 µm is provided with properties given in Table 2
[33]. Edge radius of coated tools (plain and textured) is kept at 9 µm to incorporate the effect of
coating thickness on the cutting edge. Constant coulomb friction coefficient is given as input for

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all cases. The constant friction is selected after running a number of iterative simulations. The
values are selected after checking simulation results with varying coefficient of friction ranging
0.64-0.73 and 0.44-0.56 (with 0.03 step increment) for plain and TiAlN coatings respectively
after mesh convergence tests. The cutting forces obtained from simulations are compared with
experimental results and minimum error [(Experimental value – Simulated value)/Experimental

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value] in cutting forces is considered as stopping criteria. The friction coefficient value is
selected based on minimum error in main cutting force ( ) and thrust force ( ) value for after

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simulations. In case of uncoated and TiAlN coated tools, the value of input friction coefficients
is 0.7 and 0.5 respectively taken from considering sliding friction at tool-chip interface. Similar

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values were also been considered in other studies also [29,32]. Simulations are run for uncoated,
and TiAlN coated tools at varying cutting speed and feed with plain and textured tools. Relative

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motion between workpiece and tool material were provided by fixing tool in X and Y axes from
the back side and top of the tool as shown in Fig. 2(b). Adiabatic thermal boundary conditions
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are given to the top and right boundary of the tool.

Table 3 Tool insert geometry and texture parameters

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Tool insert geometry Textured tool dimensions

Tool nose radius 0.8 mm Type of texture Chevron texture
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Tool edge radius(re) 5 µm (Uncoated) Distance from cutting edge 170 µm

9 µm (TiAlN coated)
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Orthogonal rake angle -60 Width of microchannel 60 µm

(! )
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Inclination angle ("# ) 00 Depth of microchannel 30 µm

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Relief angle ($ ) 5 Pitch 110 µm
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Fig. 2 Modeled textured grooves with (a) CAD drawing (dimensions in mm), (b) boundary conditions for
tool and (c) coating definition at tool surface for TiAlN tools
The TiAlN coating property is provided to the top layer of cutting tools and TiAlN, and WC/Co

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material properties are separately assigned to the coating layer and substrate. The top layer is
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finely meshed on the rake and flank face of the tool. The coating thickness is balanced by the
element size of the meshed tools. In the present case, minimum element size is 10 µm, and
coating thickness is adjusted accordingly to the top meshed layer as shown in the Fig. 2(c). Chip
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formation and cutting forces representation is shown in Fig 3. The forces obtained over the range
of cutting length are averaged out and used for plotting the force results.
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Table 4 Tool and workpiece meshing parameters

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Tool meshing Workpiece meshing

Relief length 2 mm Maximum element size 0.1 mm
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Maximum tool element size 0.1 mm Minimum element size 0.01 mm

Minimum tool element size 0.01 mm Mesh refinement factor 2
Mesh Grading 0.4 Maximum number of nodes 24000
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Fig. 3 Chip formation and cutting force representation for simulation results
3. Experimental methodology
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Finite element model is validated and carried for varying machining conditions by performing
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machining experiments under dry cutting conditions. Cutting experiments were conducted for
both plain and textured tungsten carbide tools (WIDIA: CNMA120408- K-20). Both plain and
textured tools are PVD coated with TiAlN coating using commercially available coating
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techniques. Coating characterization for plain and textured tools has been done by using
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scanning electron microscope (SEM: Quanta 200 FEG FESEM) and EDX (Bruker-ASX
QuanTax 200). The details are provided in the following sections with laser texturing, coating
characterizations and machining tests.

3.1 Rake face texturing of carbide tools by using nanosecond laser micromachining
Textured tools are classified on the basis of continuous and non-continuous textures. The channel
(microgrooved shape) textures at any orientation are considered as continuous textures whereas

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the micro-pits/micro-holes/micro-dots of circular, square, triangular, elliptical and any other

geometric shapes are called discontinuous textures. Chevron shaped textures are having inherent
advantage of both continuous and discontinuous texture shapes as it is a continuous chain of
single chevron unit over the textured surface. Hence, detailed experiments are carried with the
designed chevron shaped tools and the same is also used to validate the FE simulation results.

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The chevron shaped texture is selected for the cutting tools as it is having its proven advantage in
mechanical seals and novelty for cutting tool texturing. The machining experiments are

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conducted with the same textured tools for cutting force, friction coefficient and contact length.
In author’s previous study, with the help of 3D finite element studies it is confirmed that

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discontinuous textures of any shape do not affect machining results significantly [30] under dry
cutting. So, the performance of new texture shapes must be studied for machining of Ti6Al4V

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alloys by integrating with PVD coatings.
Nd:YAG nanosecond pulsed laser (Nd: YAG fiber laser, Make: Lee Laser, TQ9005, USA) has
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been used for texturing the rake surface. Laser pulses were generated at 1064 nm wavelength, 20
ns pulse duration, and frequency 20 kHz. Texture fabrication was performed at 25 mJ pulse
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energy and 50 mm/sec scanning rate. The texture dimensions measured in Fig. 4 shows texture
parameters and depth of textured geometry.
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Fig. 4. Chevron textured tools over tool rake face under 60X for (a) as fabricated, (b) diamond polished
textured tool, (c) measurement of the texture dimensions and (d) cutting edge radius measurement
3.2 Coating deposition and characterization
The tools were diamond polished and ultrasonicated in acetone for 15 minutes. Both plain and
textured tools were TiAlN coated by physical vapor deposition process. TiAlN single layer
coating was done by commercial Oerlikon Balzer’s rapid coating system (RCS) machine using

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cathodic arc evaporation (CAE) technique. To improve coating adhesion over the substrate and
remove impurities over the plain and textured surface, tools were heated and ion etched by
bombarding Ar+ ions in a vacuum environment and -150 V bias voltage. The thickness of coating
layer was 4±0.5µm. Process description and parameters are as standard Oerlikon Balzer coatings
and can be found elsewhere [34].

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Fig. 5 EDS spectra and elemental composition for (a) plain and (b) textured tools PVD coated with TiAlN

Elemental analysis for coated tools (plain and textured) was performed by energy dispersive X-
ray spectroscopy. Fig. 5 shows the elemental analysis of both the plain and textured tools coated
by TiAlN. In case of textured tools coated with TiAlN, considerable peak and element
percentage of tungsten is observed in EDS results [Fig. 5(b)]. This suggests a discontinuous

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surface architecture over cutting tools in case of textured coated tools compared to plain coated
tools. Due to laser irradiation carbonic gases evolve from WC matrix and the migration of
elements towards the surface is suspected [35]. The tungsten segregation over the laser surface
may interact with the coatings and resulting in the discontinuous surface architecture at the
interface. Due to Ti- present in the coating material, the flowing chips (Ti6Al4V) will have an

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affinity to react with the coating material. In the case of plain coated tools, the uniformity of chip
tool interaction between reactive (nascent) chip underside and coating will be high that may

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accelerate friction and chip adhesion. The presence of discontinuous hierarchy over the tool
surface will be able to reduce the uniformity of tool chip interaction. Also, it may be helpful in

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increasing coating adhesion with tool substrate. Hence, the discontinuous surface architecture on
textured coated tools is helpful in reducing cutting forces, friction, and adhesion during

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machining [36].
Vickers’ hardness test has been performed for the coated tools at applied load 20 kgf, 1 N/s
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loading rate, 2N/s unloading rate, and 10s dwell time. The high applied load is taken to consider
the combined effect of coating and texturing on the substrate. Considerable increase in hardness
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is obtained for coated textured (CT) tools due to texturing on the substrate surface. The nominal
increase in hardness values is obtained for CT tools compared to CP tools. The indent and the
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measured values for plain and textured coated tools are shown in Fig. 6. The composite hardness
of textured surface and coating increased compared to plain coated tools. The results suggest that
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the hardened layer provided to the surface due to laser irradiation increases the combined
hardness of coating and substrate.
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Fig. 6 Vickers’s hardness for different coated and textured coated tools
Fig.7 shows the atomic force microscopy images for coated plain and coated textured tools for

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topography analysis of coated surfaces. The highly rough surface is visible for the case of TiAlN
coated tools when deposited on plain surfaces compared to textured surfaces. Coatings deposited
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by PVD methods results in macroparticles formation that gives highly roughened morphology
for TiAlN coated plain tools.
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TiAlN coated
TiAlN coated tool textured tool
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Fig. 7 AFM topography for TiAlN coatings deposited on plain (CP) tools and textured (CT) tools
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Laser texturing on the rake surface provides a high surface area for the coatings during coating
deposition. The deposition of the coatings inside the textured area and around the textured space
results in the uniform coating growth. The macroparticles in coated textured tools are reduced
due to the combined effect of improved droplet separation and uniform coating growth [34]. So,
textured surfaces offer reduced macroparticles formation during coatings and show smooth
surface topography.

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3.3 Machining experiments and validation of simulated results

Ti6Al4V round bar of diameter 50 mm and length 250 mm is selected for machining
experiments. Experiments were performed on CNC turning center (Leadwell T6- Fanuc series).
K-grade tungsten carbide tools (WIDIA: CNMA120408) in combination with PCLNL-K2020
tool holder results in -60 rake angle and 50 relief angle. Uncoated plain, uncoated textured, coated

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plain and coated textured tools are abbreviated as P, T, CP and CT hereafter. Experiments were
carried at different cutting speeds, feeds and 25 mm length of cut. The depth of cut was 0.5 mm,

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and the dry environment was selected for conducting the experiments. Each experiments are
replicated three times to maintain accuracy in cutting force predictions. 3 component

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piezoelectric dynamometer (9129AA: Kistler) is used to measure and record cutting forces with
a charge amplifier (model: 5070A) connected to PC. Apparent coefficient of friction is calculated

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for performed experiments using Equation 7 and compared with that computed from FE
simulation results. Optical microscope (Stereo Discovery v20: Carl Zeiss, Germany) is used to
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measure tool chip contact length after experiments. Surface roughness of machined surface for
comparison among the finished surfaces on the basis of chip flow direction is measured in terms
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of average roughness values (Ra value). Taylor Hobson surface roughness tester is used for the
roughness measurement and five readings at three different locations have been reported.
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Corresponding 3D surface topography using ConfoMap 3D microscope is shown to depict

machined surface quality to provide a basis for chip entangling behavior in different cases.
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Experimental and FE simulations are run to evaluate the performance of textured and coated
textured tools under different levels of machining conditions (Table 5). The machining results
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considering cutting forces, friction, contact length, chip curling behavior and coating substrate
stresses are evaluated and compared with FE simulations in the following sections. Coating-
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substrate stresses are predicted for the case of TiAlN coated plain and TiAlN coated textured
tools using FE simulations and the same is correlated with coating fracture analysis at flank
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surface.
Table 5 Parameters for simulation study
Parameters Values
Cutting speed (m/min) 100, 130, 160
Feed (mm/rev) 0.1, 0.2
Tool conditions P, CP, T, CT

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4. Results and Discussion

4.1 Variation of machining forces with different tools

Table 6 shows the simulation results for different tools under different cutting conditions.
Simulation results for cutting forces were averaged over the cutting length. Variation of main

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cutting forces during machining Ti6Al4V under different simulation conditions are discussed in
this section. Fig. 8 shows the experimental and FE simulation results for main cutting forces at
varying machining parameters. There exist a close agreement in experimental and simulation

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results within 15% error range. Main cutting forces for textured tools increased by 6% compared
to plain uncoated tools. The reduction in contact area due to texturing is supposed to be helpful

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in reducing the cutting forces during machining however the contradiction exists. The increase in
cutting force for textured tools is result of texture induced chip embedding at increasing speeds.

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(a) f = 0.1 mm/rev Exp Sim

180

150
Main Cutting Force (N)

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120

90

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60

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30

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100 130 160 100 130 160 100 130 160 100 130 160
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m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min
P CP T CT

(b) f = 0.2 mm/rev Exp Sim

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300

250
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Main Cutting Force (N)

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150
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100
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50
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0
100 130 160 100 130 160 100 130 160 100 130 160
m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min
P CP T CT

Fig. 8 Variation of main cutting forces with different tools (P, CP, T and CT) at varying cutting speeds
and f = 0.1 mm/rev and f = 0.2 mm/rev

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The reason is stated as the occurrence of derivative cutting phenomenon at the rake face of
textured tools and discussed in detail later. Reduced cutting forces are obtained for CT tools and
maximum reduction is 13% for feed 0.1 mm/rev. At increased feed, the cutting force values for
textured and coated textured tools show similar trends. For coated plain and uncoated textured
tools, cutting forces increase by nominal values within 5%. The maximum reduction in case of

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coated textured tools are 15.6% compared to plain tools at 100 m/min achieved for experimental
results.

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Table 6 Comparison of simulated results for different tools (P, CP, T, and CT) under different cutting
conditions

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Feed Cutting P CP T CT
Speed

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100
m/min
AN
0.1
M

mm/rev 130
m/min
D
TE

160
m/min
EP

100
m/min
C
AC

0.2 130
mm/rev m/min

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160
m/min

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The improved performance of CT tools may be due to the combined tribological effect of
coatings and texturing on cutting tools. Reduction in cutting forces with cutting speed shows that

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incorporated J-C model with temperature dependent material properties can simulate thermal
softening nature of titanium alloys. With increasing feed up to 0.2 mm/rev, the variation of

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cutting forces over the range of cutting speed are shown in Fig. 8(b). The reduction in cutting
forces is higher for f = 0.2 mm/rev for coated textured tools. This can be explained as with
increasing feeds, more coating area is available for chip flow over the interface due to increase in

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contact length with increasing feed. The TiAlN coating becomes more effective due to its
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availability over a larger contact region and thus offers high reduction in cutting forces at
increased feed.
M
D
TE
C EP
AC

Fig. 9 Derivative cutting (IMP-µC) zone in case of machining of Ti6Al4V with textured tools

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In case of uncoated textured tools, the cutting forces increases compared to plain uncoated tools.
Due to texturing first few rows of textured tools were noticed to be highly adhere with chips. It
can be seen from simulation results [Table 6] that first two grooves of T tools were embedded by
chips. This is considered as a mechanism of chip underside cutting also termed as interface
multipoint micro cutting or derivative cutting apart from three basic machining zones in metal

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cutting (Fig. 9) [34]. It can also be verified by experimental results that first few rows of textures
gets embedded by chips during machining [Fig. 11]. However, cutting force in case of CT tools

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were reduced by 14.2%, 14.7%, and 15.6% for v = 100 m/min, 130 m/min and 160 m/min
respectively. The improved performance of CT tools again is due to reduced adherence of chips

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over textured rake face. The simulation results show that chip embedding in case of CT tools was
reduced as compared to T tools. Also, due to coating and texturing, reduced forces were

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observed as a possible effect of mechanical interlocking and coating effectiveness at higher
cutting speeds.
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4.2 Effect of textured tools on the friction coefficient
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The influence of different tools on friction coefficients in machining Ti6Al4V under different
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cutting speeds is discussed in this section. The average coefficient of friction at secondary zone
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is calculated by using Equation 7 [37].

*
% = tan ! + tan) ( * + ) (7)
,
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where ! denotes the rake angle,  is thrust force, - is main cutting force and % denotes
average coefficient of friction.
C

Fig. 10(a) illustrates the variation of frictional forces with varying cutting speeds and constant
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feed, f = 0.1 mm/rev. It shows that the friction coefficient decreases for CP, T and CT tools
compared to P tools. The percentage reduction in average friction coefficients for CP tools were
3.2-10% compared to P tools. For T and CT tools percentage reduction were 9.6-12.3% and
12.06-16.86% respectively. Fig. 10(b) shows the variation of average coefficient of friction at f =
0.2 mm/rev at varying cutting speeds. For CP tools average coefficient of friction (µ) reduces by
12.9-18.3% while the larger reduction in coefficient of friction was achieved with CT tools.

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Maximum reduction in case of CT tools achieved is 24.9% for 160 m/min. Discontinuous surface
architecture provided by coating and texturing in case of CT tools may have reduced affinity of
chips to get embedded in textures. So, this can be considered as a possible explanation for
reduced friction coefficient with coated textured tools.

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(a) f = 0.1 mm/rev Exp Sim
0.6

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0.5
Apparent coefficient of friction

SC
0.4

U
0.3 AN
0.2

0.1
M

0
100 130 160 100 130 160 100 130 160 100 130 160
D

m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min
P CP T CT
TE
C EP
AC

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(b) f = 0.2 mm/rev Exp Sim

0.8

0.7
Apparent coefficient of friction

0.6

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0.5

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0.4

0.3

SC
0.2

0.1

U
AN
100 130 160 100 130 160 100 130 160 100 130 160
m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min
P CP T CT
M

Fig. 10. Variation in coefficient of friction for different tools (P, CP, T and CT) at varying cutting
velocities and (a) f= 0.1 mm/rev and (b) f= 0.2 mm/rev
4.3 Effect of textured tools on contact length (Lc) and chip curling behavior
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One of the possible mechanisms for improved machining performance with textured tools is the
TE
C EP
AC

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reduction in tool-chip contact length (Lc). Lc increases with increase in feed, so the effectiveness
of textured tools with varying feed has been discussed in this section. Fig. 12 illustrates the
change in contact length (Lc) at varying cutting speeds and feed f = 0.1-0.2 mm/rev. From this
figure, it is clearly evident that Lc decreases for CP, T and CT tools as compared to P tools over
the range of cutting speed and feed. Contact length was found to be marginally reduced (4.6-

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14.5%) at all levels of cutting speed and feed for CP tools compared to P tools. Fig. 12(a) shows
that at f = 0.1 mm/rev and 100 m/min, experimental Lc values decreases by 68.6% and 77.2%

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respectively for T and CT tools. With the increase in cutting speed to 130 m/min, 62.9% and
68.6% reduction in Lc were observed for T and CT tools. Further reduction in Lc at 160 m/min

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were found to be 65.8% and 71.5% respectively for T and CT tools. The comparison of different
tools with respect to contact length is shown in Fig. 11(a) - Fig. 11(c).

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Fig.11 Experimental measurement of contact length for (a) plain uncoated, (b) textured uncoated and (c)
textured coated tools at . = 130 1/13, 5 = 0.2 11/78.
AN
(a) f = 0.1 mm/rev Exp Sim
0.45
M

0.4

0.35
D
Contact length (mm)

0.3
TE

0.25

0.2
EP

0.15

0.1
C

0.05

0
AC

100 130 160 100 130 160 100 130 160 100 130 160
m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min
P CP T CT

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(b) f = 0.2 mm/rev Exp Sim

0.7

0.6

PT
0.5
Contact length (mm)

0.4

RI
0.3

SC
0.2

0.1

U
0
100 130 160 100 130 160 100 130 160 100 130 160
AN
m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min m/min
P CP T CT

Fig. 12. Plot of contact length (Lc) variation for different tools (P, CP, T and CT) with different levels of
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cutting speed and (a) 0.1 mm/rev (b) 0.2 mm/rev feed
A similar reduction in Lc is observed in Fig. 12(b) for T and CT tools at f = 0.2 mm/rev over
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different cutting speeds. At 100 m/min, 50.3% and 66.7% reduced Lc were observed for T and
TE

CT tools. Reduction of 54.04% and 68.3% were observed for T and CT tools respectively at 130
m/min. The contact length in the case of textured and coated textured tools is reduced for more
than half compared to plain tools.
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Fig.13 shows the chip flow direction for different cutting tools at high-speed machining at f = 0.2
mm/rev. With plain cutting tools, the chip flow direction is directed towards the axis of rotating
C

workpiece in the direction of the secondary cutting edge (Fig. 13a). The flow of chips
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obstructing the finished work surface will cause deterioration to the machined surface. The
machining with plain cutting tools causes entangling of the chips over the machined surface and
is considered as one of the most challenging problems in machining of titanium alloys. With
textured uncoated tools, the chip flows direction changes away from the axis and chip curls
toward the primary cutting edge (Fig.13b). The continuous chip spirals away toward the
unmachined surface along the feed direction resulting in reduced chip entanglement.

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In case of TiAlN coated textured tools, the early chip curling offered by combined coating and
texturing effects. The formed chips have very low curling radius and reduced contact length
compared to plain cutting tools (Fig. 13c). The resulting chips are low in curling radius, and the
chip entanglement problems are clearly absent in this case. The combined effect of coating and
texturing is also helpful in reducing the chip entanglement apart from reduced friction and

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cutting forces. The phenomenon of reduced curling radius is also achieved by FE simulations
and is shown in Fig. 14(a). The plain tool forms chip having high radius of curvature fitted by

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outer circle in blue color whereas low curling radius chip is produced by CT tool (red circle).
The textured tool and its chip is meshed with colored whereas plain tool and corresponding chips

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are superimposed on the textured tool in yellow color. The same is experimentally evident from
machining tests (Fig.14b) that the textured coated tools are helpful in reducing chip curling

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radius when compared to plain cutting tools. The roughness values for machined surfaces in case
of plain uncoated, textured uncoated and textured coated corresponds to 0.893 µm, 0.69 µm and
AN
0.57 µm respectively. The roughness of machined surface and 3D surface topography is shown
in Fig.15 Abbott curves shows the distribution of roughness values in case of plain cutting tools
M

and coated textured tools. Coated textured tool helps in generating the workpiece surface with
lower surface finish values that is attributed to spiraling of chips away from machined surface
D

axis
and
TE

Feed direction lowe

r
EP

curli
ng
C

radi
us.
AC

Chip Flow Direction Ra value = 0.893 µm

26
a) Plain cutting tool Highly curled chips
 ACCEPTED MANUSCRIPT

PT
RI
U SC
AN
Feed direction
M
D
TE

Ra value = 0.69 µm
Chip Flow Direction
C EP

b) Textured uncoated tool Reduced curling radius

AC

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Feed direction

PT
RI
U SC
AN
Ra value = 0.57 µm
M

Chip Flow Direction Lowest curling radius

D
TE
EP

c) TiAlN coated textured tool

Fig.13 Chip flow direction for (a) plain uncoated, (b) textured uncoated and (c) TiAlN coated textured
C

tools
AC

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PT
RI
U SC
AN
M
D
TE
C EP
AC

Fig. 14 Reduced curling radius for TiAlN coated textured tools compared to plain uncoated tools evident
from (a) FE simulations and (b) metal cutting experiments

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 ACCEPTED MANUSCRIPT

PT
RI
U SC
Fig. 15 Measurement of surface topography and roughness distribution for finished workpiece
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surfaces after machining with (a) plain uncoated and (b) textured coated tools at . =
130 1/13, 5  0.2 11/78.,
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4.4 Shear stress between coating and substrate and its correlation with flank wear
In case of TiAlN coating in both plain and textured tools, shear stresses can be evaluated by
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using FE codes. Shear stresses at coating-substrate interface occur due to two major reasons. The
first reason for shear stress on coating and tool interface is the high chip flow velocity and
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heavier mechanical abrasion over the surface. This mechanical action at the coating layer causes
shear stress at the coating-substrate interface and will cause coating failure such as coating
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delamination. The second reason involves variation in thermal properties of the coating and
substrate due to cutting temperature. Variation in thermal expansion coefficient of TiAlN and
WC/Co will further lead to interface shear stress generation. By use of texturing, mechanical
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interlocking is promoted at the coating-substrate interface [38] as shown in Fig. 16(a). Under the
AC

action of high stresses, coating peel off and delamination can be prevented by using textured
tools. Fig. 16(b) and Fig. 16(c) showed the shear stress variation results by FEM simulations for
coated plain (CP) and coated textured (CT) tools. It can be seen that maximum shear stress zone
for CP and CT tools are on the flank sides of tool near the cutting edge. Coating failure is
supposed to be initiated from this zone of maximum shear stress. Also, with CP tools, maximum
shear stress zone is on the rake face at some distance away from the cutting edge. In case of CT

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tools, the zone of maximum shear stress (on rake face) is absent, and hence it can be stated that
with CT tools the chances of coating failure are reduced as shown from simulation results. Wear
micrographs for CP and CT tools are taken after machining length of 100 mm for high feed and
intermediate speed condition (. = 130 1/13, 5 = 0.2 11/78., 9: = 0.511).

PT
RI
U SC
AN
M
D
TE
C EP

Fig. 16(a) Schematic of mechanical interlocking between the coating layer and cutting tool interface, and
AC

simulation results of shear stress for (b) CP and (c) CT tools

In case of CP tools, the coating from the cutting edge and flank face is delaminated up to 110 µm
from cutting edge and is seen in Fig. 17(a). The fractured coating area is seen beyond the wear
formed over the substrate due to abrasion grooves. Once the coating is fractured/completely
delaminated, the substrate from the cutting tool edge starts to wear due to abrasion with the
finished workpiece. The FE simulation results in Fig. 16 shows the maximum stress in case of

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CP tools are highly concentrated over the flank face compared to CT tools. The high stresses in
CP tools result in shearing/fracture of coatings over the flank surface. Comparatively, CT tools

PT
RI
U SC
AN
M
D
TE
C EP
AC

have gradual substrate wear with limited coating delamination up to 80 µm (Fig.17b).

Fig. 17 Flank wear land micrographs for (a) coated plain (CP) and (b) coated textured (CT) tools

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Coating adherence to tool flank seemed to be improved in case of CT tools that resulted in the
reduced coating fracture area. Apparently, no cracks are visible on the flank surface in case of
CT tools. These results can be correlated with that obtained from FE Simulations for shear
stresses.

PT
Conclusions

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Present work reports the effectiveness of textured hard TiAlN coated tools for machining

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Ti6Al4V alloy. The effects of coating, tool edge radius, feed and cutting speed have been
simulated by using finite element codes. Experiments were carried out with coated and uncoated

U
textured tools to validate the simulations. Simulated results for cutting forces, thrust force and
contact length were found to be well in agreement with the experiments. Major findings of the
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presented article are summarized as:
(1) Textured hard TiAlN coated tool has resulted in reduced cutting forces, apparent friction
M

coefficient, contact length, and lower chip curl radius as compared to other developed
tools.
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(2) The main cutting force was reduced by 9.6-10.7% and 17-19.5% at varying feeds for CT
tools compared to uncoated plain tools. Increase in feed increases the contact length, and
TE

hence efficacy of textured and coated textured tools improves at the higher feed.
(3) Chip-tool contact length (Lc) decreases for T and CT tools compared to plain tools. A
EP

Larger reduction in contact length (>30%) is achieved with CT tools due to the combined
effect of coating and texturing.
(4) Available theoretical models are not able to predict the contact length variation in
C

machining with textured tools. So further studies can be conducted for modeling of tool-
AC

chip contact length to predict the relative variation in cutting forces with textured tools.
(5) Textured and textured coated tools can help in disentangling the chips from machined
surfaces and offer better surface finish compared to uncoated plain cutting tool. Further,
reduced curling radius improves the chip flow in case of textured coated (CT) tools.
(6) Simulation results show that maximum shear stresses on flank and rake face are reduced
for CT tools. Mechanical interlocking is proposed as a reason for the reduced chances of

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coating failure during machining. The results are experimentally validated by coating
delamination over the flank face. Coated textured tools have reduced delamination and
substrate fracture due to reduced shear stresses.

Declaration of conflicting interests

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The authors hereby mention that there exists no competing interests in the publication of the
present article.

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Acknowledgment

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Any specific funding agency doesn’t support the research article at this moment. The authors
acknowledge Central Research Facility (CRF-IIT Delhi) for SEM/EDS analysis.

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2015;276:485–501. doi:10.1016/j.surfcoat.2015.06.025.
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 ACCEPTED MANUSCRIPT

Highlights

• Plain and chevron textured tools were used with uncoated and TiAlN coatings for turning

of Ti6Al4V.

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• Cutting tests were conducted for forces, apparent friction, chip contact length, curling and

disentagling behavior for plain and textured tools.

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• Experimental results are validated for FE simulations and compared for the analysis.

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Texture induced derivative cutting phenomenon is explained with FE simulations and

experimentally validated.

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• Reduction in maximum shear stresses at flank for textured tools reduced delamination of
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coatings.
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