Modeling tool wear in titanium cutting with an in-process tribometer

Abstract

Purpose Metalworking fluids can significantly increase the tool life in titanium cutting, however, full-scale cutting tests to determine the performance of metalworking fluid are expensive. The aim of this study is therefore to introduce a reliable and inexpensive alternative testing method. Design/methodology/approach A newly developed in-process tribometer allows emulating the sliding conditions of the chip formed in cutting as closely as possible. It uses a cutting action in front of a pin to eliminate the influence of the oxidation layer. To observe the wear pattern on the pin, adhering workpiece material is removed by selective etching. A high temperature oxidation test is used to study the wear mechanism. Findings The wear pattern on the pin correlates well with the wear pattern observed on cutting tools when using the same metalworking fluid while being much more cost-effective than a tool life test. The high temperature oxidation test reveals that cobalt leaching is causing notch wear. Research limitations/implications The correlation between pin and tool wear is verified for the case of roughing turning of titanium with cemented carbide tools and two metalworking fluids. Practical implications The method is applicable in an industrial context, potentially replacing the currently used tribological analyzes. Social implications Submitted in connection with the special issue “young tribologists – insights into the work of the new generation”. Originality/value Methods tailored to model the tool wear in titanium cutting are rare. For the first time, an in-process tribometer, which is especially suited for the analysis of titanium cutting, is used to assess the wear behavior. The design of the high temperature oxidation test is new. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2019-0311 .