Int J Adv Manuf Technol (2017) 93:347–360
DOI 10.1007/s00170-016-9381-y
ORIGINAL ARTICLE
Effect of textures on machining of Ti-6Al-4V alloy for coated
and uncoated tools: A numerical comparison
D. Arulkirubakaran 1 & V. Senthilkumar 1 & S. Dinesh 1
Received: 24 June 2016 / Accepted: 22 August 2016 / Published online: 3 September 2016
# Springer-Verlag London 2016
Abstract The present investigation is to reduce the detri-
mental effects happened during machining of Ti6Al4V by
employing different types of texture patterns on the rake
face of the coated (TiN and TiAlN) and uncoated cutting
tool inserts. During 3D-Deform machining simulation, the
work material is constrained as elasto-plastic and the tool
material constrained as rigid body. The machining simu-
lation process was carried out with the updated
Lagrangian formulation, and Johnson-Cook model was
used to predict the machining forces, cutting temperature
and shear angle. A semi-solid lubricant, molybdenum di-
sulfide with SAE40 oil (80:20), was applied during the
process and the temperature at the tool-chip interface zone
was measured with the aid of a thermal imager camera.
Kistler 9257B type three component dynamometer was
used to measure the machining forces. The measured ma-
chining forces, temperature and shear angle were com-
pared with the results of 3D-Deform simulation.
Comparatively, it was found that the cutting force and
temperature were found to be minimum during machining
of Ti6Al4V alloy with TiAlN-coated perpendicular tex-
tured tool.
Keywords Numerical simulation . Deform-3D . Textured
tool . Ti-6Al-4V . Johnson-Cook . Lagrangian formulation
* V. Senthilkumar
vskumar@nitt.edu
1
Department of Production Engineering, National Institute of
Technology, Tiruchirappali, Tamil Nadu, India
1 Introduction
Titanium and its alloys are used in numerous applications such
as aerospace, ship building, nuclear reactors, chemical indus-
tries, medical implants and automobile components. During
dry turning of titanium and its alloys, the temperature pro-
duced at the tool-chip interface is high due to its low thermal
conductivity and high strain hardening behavior [1].
Deform 2D software can be effectively used to identify the
best possible experimental condition within the stipulated time
of titanium alloy and it was revealed that the simulation results
and experimental results were in good agreement [2]. Chip
shear band and chip formation phenomenon were identified
using numerical simulation on Ti6Al4V alloy using three dif-
ferent constitute models, namely hyperbolic tangent (TANH),
Johnson-Cook (J-C) and Arbitrary Lagrangian Eulerian
(ALE) formulation. It was observed that the J-C model pre-
dicted accurately the formation of shear band and chip com-
pared to other two types of models [3]. A reduction in tool
wear, cutting forces and an improvement in chip morphology
were observed during machining of Ti6Al4V alloy at higher
cutting speed. The DEFORM 2D simulation results were
found in good agreement with the experimental results [4].
Machining experiments were carried out to analyze the tem-
perature distribution during machining of AISI 1045 steel. It
was noticed that the DEFORM 3D simulation results could
yield better results than the DEFORM 2D in all aspects [5].
Ma et al. [6] investigated the effect of micro grooved tools in
machining of Ti6Al4V alloy. Groove depth, groove width and
cutting edge distance were the other factors considered. Lower
cutting forces and consequently lower energy consumption
were observed during machining with micro grooved tools
as compared to the conventional tool.
The simulation on machining of AISI52100 bearing steel
was carried out with different grooved patterns (non-textured,
348
parallel, perpendicular and rectangle) with various dimensions
(pitch size, edge distance, height of the groove). It was report-
ed that a pattern of grooved tool cut preferentially in perpen-
dicular direction to that of chip flow with groove dimensions
such as edge distance of 100 μm, pitch size of 100 μm, and
height 50 μm exhibited better performance characteristics [7].
Aluminum 6061 alloys and 1045 steel were machined with
areal and linear textured pattern. It was observed that the mea-
sured forces were decreased by 10–30 % compared to that of
non-textured tools. It was also stated that the influence of
texturing has a positive improvement in the reduction of fric-
tional force and material adhesion between the tool-chip con-
tact interface [8].
Micro-scaled textured tool with different geometrical ori-
entation patterns such as elliptical, parallel and perpendicular
were used to machine # 45 grade steel using MoS2 lubricant. It
was reported that the elliptical pattern geometry produced
more pronouncing effect than the parallel and perpendicular
texture types [9]. Four different types of geometrical textured
tools (parallel, perpendicular, pit and dot pattern) were used in
machining of A6061-T6 alloy. Reduction in friction coeffi-
cient was observed during machining with parallel and dot
type texture [10]. The effect of textured tool on machining
of Ti6Al4V alloy with the parallel, perpendicular geometrical
orientation with various groove sizes ranging from microme-
ters to nanometers were studied. A least tangential cutting
force and lesser coefficient of friction were observed during
machining with the perpendicular textured tool than other type
of tools [11]. Similar kind of investigations on machining
different hard materials with textured tool inserts were per-
formed by various authors. It was concluded that for any given
machining conditions, the textured tools have superior perfor-
mance than the non-textured tools [12–27]. Tool wear was
analyzed during machining different hard materials with sin-
gle layer and multilayer coated tools. It was stated that the
performance of multilayer coated tool (TiAlN) exhibits better
hardness and thermal stability than the uncoated tools [28].
The performances of various coatings (TiN, TiC, TiAlN,
TiCN and Al2O3) on cutting tools were analyzed during ma-
chining of Ti-based alloys and stainless steel material. It was
stated that the coated tools exhibited better results than the
uncoated tools for all the given machining condition [29,
30]. The performance of coated and uncoated tools during
machining of 17–4 PH stainless steel was compared. It was
found that the flank wear was less and the surface finish was
good during machining with multilayer coated tool inserts
[31]. The machinability of laser surface treated PH stainless
steel with TiAlN-coated tools was investigated. Reduction in
cutting force and better surface quality was observed during
machining with coated tools [32]. The tool wear during ma-
chining of Ti6Al4V alloy and Inconel 718 with coated and
uncoated inserts were analyzed. It was observed that the wear
resistance was superior for the coated tools than the uncoated
Int J Adv Manuf Technol (2017) 93:347–360
tools [33]. Machinability in terms of cutting force and tool
wear was analyzed using coated-surface textured inserts
(TiAlN, Ti55Al45N, WS2 self-lubricated). Authors have re-
vealed that the coated-surface textured inserts exhibit better
performance than the uncoated textured and non-textured in-
serts [34–41].
The current work deals with the simulation of turning pro-
cess on Ti6Al4V alloy using coated and uncoated cutting in-
serts. Various textured cutting tools with different orientation
to the chip flow direction were modeled using 3D modeling
software. Deform-3D software was applied for the numerical
simulation of turning process. The performance of textured
inserts during machining Ti6Al4V alloy was evaluated by
means tangential cutting force, machining temperature and
shear angle with the simulation. The predicted results were
compared with that of experimental results for the both coated
and uncoated tools.
2 Machining processes
2.1 Simulation of machining process
Deform 3D software package was used for the simulation
of machining process. It depends on the Lagrangian for-
mulation (updated) with integration (implicit) method.
Ti6Al4V alloy with Ф 25 mm was considered as work
material, and it is defined as elasto-plastic material. The
empirical equation of Johnson-Cook constitutes the model
shown in equation (1), and related empirical constants as
furnished in Table 1 were used to find out stress during
machining [22, 23, 41].
  :    
ε T −T 0 m
ε Þn  1 þ Cln :
σ ¼ ½A þ Bð ̅ 1− ð1Þ
ε0 T melt −T 0
For obtaining closer mesh density, work material was con-
sidered as a curved model with curvature angle of 20°. The
fixed constraints were used in all directions. A continuous
adaptive re-meshing technique was followed in simulation
using DEFORM 3D package. Twelve thousand tetrahedral
elements were taken for the work piece material. PRO-E
Wildfire 5 software was used to model the surface textured
cutting tools with grooves that were cut along the preferred
Table 1 J-C material
model coefficients for A (MPa) 968
Ti-6Al-4V alloy B (MPa) 380
n 0.421
C 0.0197
m 0.0577
Room temperature (°C) 25
Melting temperature(°C) 1604
Int J Adv Manuf Technol (2017) 93:347–360
orientation such as non-textured, parallel and perpendicular
direction to that of chip flow. Inserts with CNMA 120408 tool
geometry and texture dimensions of 250 μm × 100 μm were
considered.
3D tool model with grooves in different orientation with
the coating material properties such as thickness and related
tool material properties were imported into the 3D Deform
software package during formulation of machining simula-
tion. The cutting tools were defined by 14,000 elements and
cutting tool tip was re-meshed with 1,00,000 elements for the
better distribution of output parameters like temperature and
friction co-efficient. Thermal boundary conditions are given
in equation (2) to allow the heat transfer and heat conduction
from the work material to the tool inserts at tool-chip contact
pressure [21].
 
kw
H ¼ 442−2:36ν−7950 þ 0:276ν 2 þ 40600f 2 ð2Þ
m2 K
Where v is the cutting speed (m/min) and f is the feed rate
(mm/rev).
The 3D numerical simulation modeling, constant shear
friction factor (m), coulomb friction factor (μ) and pressure
dependent shear friction factor (p) are required to find the
friction effects between tool geometry and the work piece.
3D finite element modeling simulation of machining process
was processed with different rotational speeds, feed rates and
axial depth of cut. A trouble-free trial-and-error approach was
utilized to examine the friction models for calibrating finite
element simulation outputs. Further, simulation was done with
textured tools after the initial trial simulation. The resultant of
pressure-dependent friction was considered for the 3D process
simulation. The results after completion of simulation such as
cutting forces, temperature and chip morphology were vali-
dated with experimental results.
2.2 Experimental procedure
The turning experiments were carried out with Ti6Al4Valloys
with a Ф of 25 mm and length 125 mm using the modified
surface textured cutting tools. Fig. 1 shows the schematic di-
agram of experimental procedure and Fig. 2 shows the differ-
ent types textured tools produced by wire EDM process.
Machining conditions are shown in Table 2. The properties
of work material and tool are shown in Tables 3 and 4. The
Titanium nitride (TiN) and titanium aluminum nitride (TiAlN)
materials were coated with the thickness of 4 μm on the tex-
tured tool inserts using physical vapor deposition (PVD) tech-
nique. The SEM with (EDS) analysis of TiN coating and
TiAlN coating are shown in Fig. 3a, b. The coating thickness
was verified through EDS analysis. Figure 4 shows the tem-
perature profile of secondary deformation zone captured using
thermal imager camera. The hardness of different coated tools
349
are provided in Table 5 and are in good agreement with the
literatures found elsewhere [30].
3 Results and discussion
3.1 Effect of texture on cutting force
Figures 5a–c show the effect of texture on the cutting forces
under simulated condition for different types of coated and
uncoated tools for the given cutting speed condition. From
Fig. 5a, a maximum of 165 N cutting force was observed for
the NT tool during numerical simulation at a cutting speed of
60 m/min. Generally, textured tools reduces the cutting force
than the non-textured tool for any given cutting speed condi-
tion. A minimum cutting force of 143 N was noticed with
PE.T uncoated tool at 60 m/min under the simulated condi-
tion. When the cutting speed increases from 60 to 120 m/min,
a cutting force of 151 N was observed with NT (uncoated) tool
and 118 N for the PE.T (uncoated) tool under simulated con-
dition (Fig. 5c). The reduction in cutting forces as the speed
increases is due to the thermal softening effect and reduced
friction between the tool-chip interface. These results were in
good agreement with machining trial data and with the earlier
data available in literature [8, 11]. However, coated tools are
recommended for the turning of hard materials like Ti6Al4V
alloys due to their excellent functional properties such as
higher thermal stability, high hardness, and reduction in fric-
tional effect between tool-chip and tool-work interfaces. From
Figs. 5a–c to 6a–c, the cutting force of coated tools were
minimized as compared to uncoated tools for any given cut-
ting speed due to its reduction in friction and lesser contact
area between tool-chip interface which resulted in reduction of
cutting forces.
As shown in Fig. 5a under simulated condition, at a cutting
speed of 60 m/min, a reduction in main cutting force by 12 and
22 % was observed respectively for TiN- and TiAlN-coated
non-textured tools as compared to those values predicted for
the uncoated tool. Better surface finish, thermal stability, and
reduction in friction at the tool-chip interface are the important
factors for the reduction of force. A maximum cutting force of
145 N was measured with TiN coated non-textured tool which
was 10 % higher than that of TiAlN-coated tool at a cutting
speed 60 m/min. Force reduction in case of TiAlN coated tool
can be attributed to its properties such as better adhesion
strength, good surface finish, and less coefficient of friction
as compared to TiN coating [30]. From the results of numer-
ical simulation, it can be observed that there was a reduction in
cutting force of about 6–22 % when machined with TiN,
TiAlN coated textured tools than the uncoated textured tools.
Moreover, it was found that there was a reduction in tool chip
contact length and coefficient of friction. In addition, the fric-
tional co-efficient was reduced by the application of semi-
350 Int J Adv Manuf Technol (2017) 93:347–360

Fig. 1 Schematic diagram of

experimental work

solid lubricant between the contact surfaces of tool and chip of cutting forces. Similar effects were observed for other
that reduced the cutting force. cutting speeds such as 90 and 120 m/min for all the given
The chip formed during machining had more contact tool types (Fig. 5b, c). The results of experimental condi-
with the tool rake face in case of parallel and cross tex- tions and simulated conditions were similar as shown in
tured pattern in both uncoated and coated conditions com- Fig. 6a–c and as reported in the earlier literature [5, 6, 36,
pared to that of the perpendicular textured tool; hence, 37, 41].
more cutting forces were observed with simulated condi-
tion. From Fig. 5c, low cutting forces were observed for
TiAlN coated perpendicular textured tool as compared to Table 2 Experimental cutting conditions
other tools for given machining conditions. Superior prop-
Work material Ti-6Al-4V titanium alloy
erties of TiAlN coating and reduction in friction proper- (material properties as shown in Table 3)
ties of textured tool surfaces contributed to the reduction
No. of experiments 36
Tool insert Tungsten carbide (CNMA 120408)
with TiN, TiAlN-coated tools
(material properties as shown in
Table 4)
Coating thickness 4 μm
Type of texture pattern used Non-texture (NT), perpendicular texture
(PE.T),
Parallel texture (PR.T), cross-texture
(CR.T) with a groove width of 250
μm and depth of 100 μm
Dynamometer KISTLER piezoelectric dynamometer
(Kistler Type 9257B)
Temperature Fluke thermal imager camera
Lubricant Semi-solid lubricant [molybdenum
disulfide MoS2 (80 wt.%) mixed
with gear oil (20 wt.%)]
Cutting velocity (m/min) 60, 90, 120
Feed (mm/rev) 0.1
Fig. 2 Different types of textured tools produced by wire EDM Depth of cut (mm) 0.5
process [41]
Int J Adv Manuf Technol (2017) 93:347–360 351

Table 3 Properties of Ti-6Al-4V titanium alloy [24] perpendicular textured tools were observed for the other range
Mechanical and thermal properties Ti-6Al-4V of machining parameters (90 and 120 m/min) and the same is
shown in Fig. 8a–c. The above results are in good agreement
Density (g/cm3) 4.43 with the reported literatures elsewhere [5, 6].
Tensile elastic modulus (GPa) 110
Tensile strength (MPa) 931
Yield strength (MPa) 862 3.3 Effect of texture on feed force
Elongation (%) 14
Thermal conductivity at 20 °C (W/m K) 7.3 Feed forces (Fy) produced during the simulation of Ti6Al4V
Specific heat 20–100 °C (J/kg K) 709 with various tools for different cutting speeds are shown in
Hardness (HV10) 340 Fig. 9a–c. Feed forces were found to be minimized in case of
coated textured tools. The highest feed force of 116 N
(Fig. 9a) was found during machining of titanium alloy using
3.2 Effect of texture on thrust force uncoated non-textured tool at a machining speed of 60 m/min.
However, for the same machining conditions, uncoated inserts
Thrust forces (Fy) observed during machining simulation of with perpendicular texture produced a minimum force of
Ti6Al4V for different cutting tools for any given cutting 89 N. Better lubrication effect in case of perpendicular texture
speeds are shown in Fig. 7a–c. Thrust forces were found to tool can be attributed to feed force reduction.
be minimized in case of coated textured tools. A highest thrust During machining with coated inserts, the reduction in feed
force of 124 N (Fig. 7a) was observed for the uncoated non- force was in the range of 16–35 % as compared to that of
textured tools at a machining speed of 60 m/min. However, for uncoated inserts. Reduction in tool-chip contact length and
the same machining conditions, the thrust force observed was better surface properties of both coatings (TiN and TiAlN)
minimum (100 N) while machining with perpendicular tex- caused less force generation compared to that of uncoated
tured tools with better lubrication effect and low tool-chip tools.
contact length. A least feed force of 59 N was measured for TiAlN coated
Compared to that of uncoated tools, a reduction in thrust perpendicular textured tool. An integrated effect of enhanced
force by 16–35 % was noticed when machining with coated lubricity and better surface roughness properties of TiAlN
inserts. Good surface properties of both coatings (TiN and coating can be attributed to the reduction in tool wear in case
TiAlN) caused less force generation. Especially, the thrust of perpendicular texture tool. A similar trend was observed for
forces produced by TiAlN coated tools were less due to its the other experimental and simulated machining conditions
coatings retention of higher thermal stability and tool wear (90 and 120 m/min) as shown in Fig. 10a–c.
resistance at elevated temperature.
A minimum thrust force (49 N) was measured for TiAlN 3.4 Effect of texture on friction co-efficient
coated perpendicular textured tool. An integrated effect of
enhanced lubricity and reduction in tool-chip contact length
The coefficient friction (μ) at the tool–chip formation zone is
reduced the tool wear of perpendicular textured tool. A similar calculated based on orthogonal machining theory [16]
trend of reduction in thrust force during machining with
  
Fy
μ ¼ tanðβÞ ¼ tan ∝ þ arctan ð3Þ
Fz
Table 4 Material properties of tool material [23, 24]
Where α is the rake angle, β is the friction angle, Fy is the
Tool material property WC-6%Co
radial thrust force, and Fz is the main cutting force.
(Tungsten carbide-WC)
Figure 11a–c shows the friction at the tool-chip interface
Hardness (HV10) 1485 occurred during turning of Ti6Al4V alloy with different tex-
Hot hardness 800 °C (kg/mm2) 600 tured and non-textured tool condition for the TiN and TiAlN
Thermal conductivity (W/mK) 45 coating under semi solid (MoS2) lubricant cutting conditions.
Modulus of elasticity (GPa) 620 The trend of friction co-efficient values was similar to that
Poisson coefficient υ 0.26 of cutting forces for the both experimental and simulated con-
Density (g/cm3) 11.4 ditions. An effective reduction in the friction coefficient was
Thermal expansion (10–6/K) 6.1 observed with PE.T tool for any given cutting speed. For both
Traverse rupture (GPa) 2.2 experimental and simulated conditions, 5–10 % reduction in
Grain size (μm) 1 to 5 friction coefficient was observed in case of perpendicular tex-
ture tool than other types of tools [6, 7, 15].
352
Fig. 3 SEM with (EDS) analysis.
a TiN coating. b TiAlN coating
Textures on the rake face of cutting tool reduce the tool-
chip interface contact length. Moreover, coating properties of
tool material and usage of MoS2 semi-solid lubricant mini-
mize the friction between the tool-chip interface and thereby
reduce the heat generated during machining.
The reduction in tangential cutting force was more due to
the lubrication and unique properties of the TiAlN coating.
The reduction in friction coefficient was found to be low with
Fig. 4 Temperature profile of secondary deformation zone captured
using a thermal imager camera
Int J Adv Manuf Technol (2017) 93:347–360
coated textured tools than the uncoated non-textured tools.
Compared with higher cutting speed, a lower cutting speed
causes higher coefficient of friction for all the texturing con-
dition [18].
Moreover, at higher cutting speed and all tool conditions,
the decrease in friction coefficient is due to the thermal soft-
ening effect over the strain hardening. Among all the types of
surface textured tools, the coefficient friction value was less
for the perpendicular textured tools with TiAlN coating due to
the formation of thin lubricating film coupled with superior
properties of coated cutting tools.
3.5 Effect of texture on temperature
Figure 12a–c shows the temperature measured at tool-chip
interface during simulation of Ti-6Al-4V with coated and
Table 5 Hardness for
different coated tools Coating materials Micro hardness
[28] (HV25 g)
Uncoated 1600
TiN 2950
TiAlN 3450
Int J Adv Manuf Technol (2017) 93:347–360 353

Fig. 5 Effect of texture

orientation on cutting forces
under simulated condition for
different types of coated and
uncoated tools. a 60 m/min. b
90 m/min. c 120 m/min

Fig. 6 Effect of texture

orientation on cutting forces
under (Exp Vs Sim) condition for
coated and uncoated tools. a
60 m/min. b 90 m/min. c 120 m/
min
354 Int J Adv Manuf Technol (2017) 93:347–360

Fig. 7 Effect of texture

orientation on thrust forces under
simulated condition for coated
and uncoated tools. a 60 m/min. b
90 m/min. c 120 m/min

Fig. 8 Effect of texture

orientation on thrust forces under
(Exp Vs Sim) condition for
different types of tools. a 60 m/
min. b 90 m/min. c 120 m/min
Int J Adv Manuf Technol (2017) 93:347–360 355

Fig. 9 Effect of texture

orientation on feed forces under
simulated condition for coated
and uncoated tools. a 60 m/min. b
90 m/min. c 120 m/min

Fig. 10 Effect of texture

orientation on feed forces under
(Exp Vs Sim) condition for
different types of tools. a 60 m/
min. b 90 m/min. c 120 m/min
356
Fig. 11 Effect of texture
orientation on friction co-efficient
under (Exp vs Sim) condition for
uncoated tools and coated tools. a
60 m/min. b 90 m/min. c 120 m/
min
uncoated textured and non-textured cutting tool conditions.
The temperature during machining was calculated by taking
five repeated trials at an interval of 2 seconds with different
machining speeds namely 60, 90, and 120 m/min for all the
coated and uncoated tool conditions. Minimum machining
temperature at the tool-chip interface was found to be
471 °C at 60 m/min, and it was increased to 561 °C at
120 m/min in the case of PE.T tool as compared to other type
of tools (Fig. 12a). Similar behavior was observed for both
TiN and TiAlN coated cutting tools.
The temperature distribution during machining was plotted
for the simulated condition and is shown in Fig. 12c.
Machining temperature was measured for PE.T tool as
471 °C at 60 m/min and 561 °C at 120 m/min for the uncoated
tools. Figure 13c shows a temperature comparison of
experimental and simulated conditions for the coated,
textured, and uncoated tools at various cutting conditions.
During machining with PE.T tools, it was observed that at
higher cutting speeds, reduction in temperature in the range of
17–23 % and 16–24 % was observed for experimental and
simulated conditions. Similarly, for the TiN coated tools, a
reduction of 16–31 % and 18–32 % for TiAlN coated tools
was observed under simulated condition. Similar trend of tem-
perature distribution was observed with the experimental data
for the TiN and TiAlN coated tools, and same is shown in
Fig. 13a–c. Figure 14a–d shows the temperature during the
Int J Adv Manuf Technol (2017) 93:347–360
machining simulation for the different types of uncoated,
coated, textured, and non-textured tools. However, textured
surfaces with TiAlN coating and with MoS2 semi solid lubri-
cant improve the machinability of Ti6Al4V alloy by means
micro-pool lubrication mechanism. Less tool-chip contact ar-
ea with textured tool resulted in lesser frictional coefficient
and thereby reduced the cutting temperature.
Moreover, for any given cutting speeds, a significant reduc-
tion in the temperature was noticed (19–32 %) during simula-
tion using TiAlN coated inserts with perpendicular texture as
shown in Fig. 14d. Temperature reduction can be attributed to
effective heat transfer with TiAlN coating along the chip-tool
contact area, less coefficient of friction, and better lubrication
effect [15].
3.6 Effect of texture on shear angle
The shear angle is calculated based on the empirical relation
(4) for the experimental condition and simulation condition as
reported in the earlier literature [13]
 rcos∝ 
ϕ ¼ tan−1 ð4Þ
1−rsin∝
ϕ = shear angle in degrees, r = chip thickness ratio, ∝ = rake
angle in degrees.
Int J Adv Manuf Technol (2017) 93:347–360 357

Fig. 12 Effect of texture

orientation on temperature under
simulated condition for coated
and uncoated tools. a 60 m/min. b
90 m/min. c 120 m/min

Fig. 13 Effect of texture

orientation on temperature under
(Exp vs Sim) condition for coated
and uncoated tools. a 60 m/min. b
90 m/min. c 120 m/min
358 Int J Adv Manuf Technol (2017) 93:347–360

Fig. 14 Temperature during the

machining simulation for the
different types of tools. a 60_NT_
uncoated. b 60_PE.T_TiAlN
coated. c 120 _NT_uncoated. d
120_PE.T_TiAlN coated

The chip is sectioned in the middle portion using slicing
option available in Deform 3D (Fig. 15a), and it is converted
as two-dimensional representation and the necessary chip
thickness is measured using Auto-Cad software. The mea-
sured values are used to calculated the shear angle for all given
cutting speed conditions.
Based on the discussion in the previous sections, the shear
angle measurement was predicted for the best performing tool
(perpendicular texture in the present case) and non-textured
tool under coated and uncoated condition for different cutting
speeds, and the values so measured were compared with
experimental data. From Fig. 15b, it is measured that under
experimental conditions and at 60 m/min, the shear angle is
found to be 40.8° for uncoated non-textured tool and 41.8° for
PE.T uncoated non-textured tool. When the cutting speed is
increased from 60 to 120 m/min, the shear angle decreased for
the non-textured and PE.T tools. From the experimental re-
sults, the shear angle measured is found to be 41.48° for non-
textured TiN coated tool and 43° for PE.T textured TIN coated
tool. TiAlN coated tool produces an increase in shear angle
(42.4°) for the non-textured and (44.6°) PE.T textured tool.
Especially, TiAlN coated with PE.T tool produces an increase

Fig. 15 Effect of texture

orientation on shear angle
measurement for the different
machining condition. a Sliced
chip. b Experimental. c Simulated
Int J Adv Manuf Technol (2017) 93:347–360
in shear angle for all the given cutting speed conditions. The
above findings are good in agreement with simulated data
(Fig. 15c).
4 Conclusions
Different types of textures were prepared on the tool rake face
of the WC/Co carbide tools using Wire-EDM Process. The 3D
tool model was developed for DEFORM-3D simulation using
PRO-E modeling software. Turning operations were done at
different cutting conditions using molybdenum disulfide with
SAE 40 oil as semi-solid lubricant for the uncoated, TiN and
TiAlN coated tools. From the experimental and simulation
results, the following conclusions are drawn.
1. Machinability of Ti-6Al-4V alloy was noticeably in-
creased with perpendicular textured (PE.T) tool for un-
coated, TiN coated and TiAlN coated tools. However,
TiAlN coated PE.T tool showed better results than the
other types of tool under experimental and simulated
conditions
2. The resultant machining forces were found to be less in
PE.T tool for all the machining conditions and are in good
correlation with experimental and simulated data
3. Reduction in frictional effect was seen in the textured tool
condition for both the experimental and simulated data.
4. TiAlN coated tools with perpendicular texture pattern in-
crease the shear angle.
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