Experimental Characterization of Tool Wear Morphology and Cutting Force Profile in Dry and Wet Turning of Titanium Metal Matrix Composites (Ti-MMCs)

Metal-matrix composites (MMCs) are made of non-metallic reinforcements in metal matrixes, which have excellent hardness, corrosion, and wear resistance. They are also lightweight and may pose a higher strength-to-weight ratio as compared to commercial titanium alloys. One of the MMCs with remarkable mechanical properties are titanium metal matrix composites (Ti-MMCs), which are considered a replacement for super-alloys in many industrial products and industries. Limited machining and machinability studies of Ti-MMCs were reported under different cutting and lubrication conditions. Tool wear morphology and life are among the main machinability attributes with limited attention. Therefore, this study presents the effects of cutting and lubrication conditions on wear morphology in carbide inserts when turning Ti-MMCs. To that end, maximum flank wear (VB) and cutting forces were recorded, and the wear morphologies within the initial period of the cut, as well as the worn condition, were studied under dry and wet conditions. Experimental results denoted that despite the lubrication mode used, abrasion, diffusion, and adhesion mechanisms were the main wear modes observed. Moreover, built-up layer (BUL) and built-up edge (BUE) were the main phenomena observed that increase the tendency of adhesion at higher cutting times.