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Performances of concave and convex microtexture tools in turning of Ti6Al4V with lubrication

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Abstract

The microtexture is gaining more and more attention due to its unique and excellent properties in metal cutting. However, most researchers currently only pay more attention to the performance of microtextures in dry cutting, but less on the performance under lubrication conditions. Some researches show that the microstructure performs better under lubrication conditions. In addition, most people only focus on the cutting performance of a single microtexture, and there are few studies on composite microtextures. In this study, a 2D finite element model and a fluid lubrication model of metal cutting were established by finite element software, and the cutting fluid model was introduced into the 2D finite element model. The cutting process of cuting the Ti6Al4V alloy under the auxiliary lubrication of cutting fluids was successfully simulated. The convex volcano-like texture (VLT) in this paper is a composite microtexture. At the same time, a new bionic microtexture tool is proposed to solve the problem of weakened the structural strength of the tool caused by the machining microtexture on the tool. The simulation results of cutting the Ti6Al4V alloy in both dry and wet conditions show that the cutting results of the bionic microtexture tool are superior to those of the conventional tool in both cases, and the processing effect under lubrication is greatly improved. This paper also presented a new lubrication method—small quantity lubrication (SQL), which uses up to 3.14% of the amount of lubricant required by the traditional immersion lubrication (TIL). This lubrication method makes the cooling lubrication effect even better than that of TIL, besides greatly saving cutting fluids. This paper revealed the mechanism of microtexture tools cutting under lubrication conditions, solved the problem of weakened of tool strength by machining microtexture, and proposed a new efficient, green, and economical lubrication method.

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Funding

This work was supported by the National Natural Science Foundation of China (Grant Nos. 51205246 and 51775328)

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Authors and Affiliations

  1. Shanghai University of Engineering Science, Shanghai, 201620, China

    Qianxi Yu, Xu Zhang, Xuchao Miao, Xin Liu & Liqiang Zhang

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  1. Qianxi Yu
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  2. Xu Zhang
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  3. Xuchao Miao
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  4. Xin Liu
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  5. Liqiang Zhang
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Correspondence to Xu Zhang.

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Yu, Q., Zhang, X., Miao, X. et al. Performances of concave and convex microtexture tools in turning of Ti6Al4V with lubrication. Int J Adv Manuf Technol 109, 1071–1092 (2020). https://doi.org/10.1007/s00170-020-05656-5

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  • DOI: https://doi.org/10.1007/s00170-020-05656-5

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