Numerical simulation on the machining characteristics of titanium alloy (Ti6Al4V) with coated inserts of different geometrical features

The performance improvement in machining characteristics of titanium grade 5 alloy (Ti6Al4V) is investigated in this work by turning with TiC-coated inserts of dissimilar rake angle, nose radius, and relief angle. Machining Ti6Al4V is difficult as it possesses lower heat conductivity, high-temperature strength, high reactiveness to chemicals, and high hot hardness. For this, coated inserts are considered to have varying geometries that produce better output conditions. Based on Taguchi's orthogonal array, investigations were devised, an L9 array was considered, and numerical simulation of the turning process was performed on Deform-2D simulation software. The output parameters resulting from cutting force (RFC), wear depth (WD), and tool-workpiece interface temperature (TWIT) are measured and optimized using a multi-criteria decision-making (MCDM) approach. Outcomes show that with coated inserts, the WD, TWIT, and RCF produced were lower, had a higher nose radius, and had moderate relief and rake angle, which produced better results. The confirmation experiment provides a better condition than the L9 combination.