目的 针对TC4钛合金切削过程中刀具易发生黏附磨损、切削温度高和切屑不易断裂等问题,研究不同刀具表面微织构形貌对切削性能的影响规律。方法 设计平行槽、垂直槽、网格沟槽三种普通类型及盾鳞、六边形、月牙形、菱形四种仿生类型的刀具表面微织构。在上述微织构方案基础上,采用ABAQUS建立TC4三维正交切削有限元仿真模型,从切削力、切削温度和切屑形态三个方面系统评估各类微织构的作用效果。结果 与无织构刀具相比,微织构刀具能有效降低切削力,增强刀具散热能力,从而降低切削区域温度;同时,微织构使切屑形态由带状转变为更易断裂的C型,显著减少切屑在刀具表面的黏结。其中,盾鳞微织构在改善切削性能方面表现最为显著。结论 刀具表面微织构可有效提升钛合金切削性能,通过降低切削力与切削温度、改善切屑形态,缓解刀具黏附和磨损,进而延长刀具寿命。在所述微织构中,盾鳞微织构具有较优的综合效果。
Abstract
This work evaluates whether micro-textures on the rake face can mitigate adhesion-dominated wear tendencies in TC4 titanium alloy cutting by reducing cutting force, lowering cutting zone temperature, and promoting more favorable chip morphology. The main contribution is a controlled comparison of seven texture morphologies under the same cutting condition and comparable feature scales, and a mechanism-oriented interpretation that links force, temperature, and chip form to texture-controlled contact and secondary cutting at texture edges. Seven textured tools and one non-textured baseline tool are built as three-dimensional models. Tool geometry is fixed with rake angle 0° and clearance angle 6°. With YG8 cemented carbide as tool material, the tool is treated as a rigid body that moves linearly at constant speed. The TC4 workpiece is deformable with dimensions 5 mm by 0.8 mm by 1 mm. The bottom and two side faces of the workpiece are fixed. A partition based meshing strategy is used. The primary deformation zone and the tool chip contact region are refined. The texture region receives additional local refinement to resolve steep stress and temperature gradients near micro-features. The TC4 constitutive law is described by the Johnson-Cook model, with the parameters set as follows: A=875 MPa, B=793 MPa, C=0.01, n=0.386, and m=0.71. Thermo-mechanical properties are assigned to enable heat generation and conduction effects. TC4 thermal conductivity is 6.8 W/(m·K) and YG8 thermal conductivity is 79.6 W/(m·K). Cutting performance is evaluated at cutting speed 90 m/min and depth of cut 0.2 mm. Output metrics are the three force components, average total cutting force, temperature field near the cutting edge, and chip morphology evolution. Texture designs cover three conventional patterns and four bionic patterns. Parallel grooves, perpendicular grooves, and grid grooves share width 50 μm, depth 30 μm, and pitch 150 μm. Shield scale texture uses depth 10 μm with 300 μm spacing in both directions. Hexagonal texture uses groove width 50 μm, depth 10 μm, and inscribed circle diameter 150 μm. Crescent texture uses depth 20 μm with horizontal spacing 200 μm and vertical spacing 300 μm. Diamond texture uses width 50 μm and depth 30 μm. The baseline model is verified by comparing the simulated steady main cutting force. The simulated mean main cutting force is 385.61 N, while the empirical value is 408.84 N. The relative error in steady cutting is 5.68%, supporting the credibility of the FE framework for comparative texture evaluation. To further verify the reliability of the model, cutting experiments with an untextured tool are carried out, and the simulated main cutting force is compared with the experimental result. The average simulated and experimental main cutting forces are 394.84 N and 391.92 N, respectively, with a relative error of 0.74%, indicating that the model can reasonably reflect the cutting behavior of TC4 titanium alloy. All textures reduce the average total cutting force relative to the non-textured tool. The non-textured tool produces an average total force of 390 N. The textured tool produces 278 N for parallel grooves, 261.7 N for perpendicular grooves, 268.5 N for grid grooves, 252.8 N for shield scale, 270.4 N for hexagon, 370.4 N for crescent, and 267.3 N for diamond. The shield scale texture deliveries the largest reduction, 35.2%. The crescent texture deliveries only about 5% reduction and shows stronger force fluctuation. Temperature field comparisons show that most textures improve heat dissipation and reduce the cutting edge temperature relative to the non-textured tool. The shield scale texture produces the lowest temperature response, and the second perpendicular grooves. In contrast, the hexagonal texture exhibits the fastest temperature rise and can exceed the non-textured case, indicating that bio-inspired geometry does not guarantee thermal benefit under identical feature scales. Chip morphology changes in a texture-dependent manner. Ribbon-like continuous chips occurs for the non-textured tool, the shield scale texture, and the crescent texture. Curled C-type chips are promoted by parallel grooves, perpendicular grooves, grid grooves, hexagon, and diamond. A quantitative indicator is identified from the stress field orientation in the workpiece deformation zone. Ribbon chips correspond to a peak stress direction angle below 45°, with values 41.7° for non-textured, 39.6° for shield scale, and 43.9° for crescent. C-type chips correspond to angles at or above 45°, with values 48.2° for parallel, 45° for perpendicular, 46.2° for grid, 47.1° for hexagon, and 49.4° for diamond. The simulations support a combined mechanism. Micro-textures reduce the real tool chip contact area, lowering frictional contribution to cutting force and weakening adhesive bonding. Micro-feature edges intermittently engage the flowing chip and generate localized stress concentration. This produces secondary cutting and enhanced chip curling, and it leaves periodic grooves on the chip underside consistent with the texture spacing. The stress orientation change provides a field-level explanation for the observed transition from ribbon to C-type chips. Within the tested designs and conditions, shield scale texture offers the best overall performance by achieving the largest force reduction and the strongest temperature reduction trend, while also suppressing chip adhesion. The study also identifies a key design warning. Certain bionic shapes can increase thermal load even when force decreases, so morphology must be selected through coupled thermo mechanical evaluation rather than imitation alone.
关键词
微织构刀具 /
钛合金 /
切削力 /
切削温度 /
切屑形态
Key words
micro-textured tools /
titanium alloy /
cutting force /
cutting temperature /
chip morphology
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基金
陕西省技术创新引导计划项目（2025QCY-KXJ-053）
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