Influence of micro-textured polycrystalline diamond tools on the machining performance of titanium alloy Ti-6Al-4V in dry turning

The influence of textured patterns on polycrystalline diamond (PCD) tool inserts during dry turning of Ti-6Al-4V was investigated. Four different texture patterns were created on the rake face of the insert by laser irradiation. The results showed that the textured tools improved the machinability of Ti-6Al-4V. The cutting force was less and the surface finish improved, while tool wear was minimized. The enhancement in machining performance was attributed to shortening of contact length, increased shear angle, better anti-adhesion, debris removal, and lower vibration. The typical serrations on the chip surface were brought down. The machined surface displayed minimal material transfer and feed mark ridges. The diagonal pattern (DP) tool provided the best machining characteristics (an improvement of 34% in cutting force and 37% in surface finish at 150 m/min), when compared to other textured patterns considered.