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<p>This study investigates the effects of tool wear and tool geometry on machining performance during high-speed cutting of TC4 titanium alloy under cryogenic cooling conditions. A finite element model was developed to simulate the influence of flank wear width (VB) and tool nose radius (<i>R</i>) on cutting force, cutting temperature, and residual stress. Selected experiments were conducted to validate the simulation results. The findings reveal that increasing VB and <i>R</i> leads to higher cutting forces, with this trend being more pronounced under cryogenic conditions. When the tool nose radius was 0.2&#xa0;mm, the cutting temperature decreased by 13.9% compared to dry cutting. At VB = 0.2&#xa0;mm, cutting force exhibited an “<i>N</i>-shaped” variation with environmental temperature. Cryogenic cooling significantly improved residual stress distribution on the machined surface. At − 142&#xa0;°C, the range of compressive residual stress increased by 5% and its maximum value improved by 8% relative to − 196&#xa0;°C. Additionally, a tool life prediction model under low-temperature conditions was developed, providing practical guidance for optimizing TC4 machining processes. These findings contribute to a better understanding of cryogenic machining and support its application in high-performance titanium alloy processing.</p>

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Investigation of Tool Wear and Dimensional Effects in High-Speed Machining of TC4 Titanium Alloy under Cryogenic Conditions

  • 期刊论文

  • 发表日期：

    2026年7月6日

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  • Ping Zhang,
  • Yiming Zheng,
  • Fang Wang,
  • Bingbing Li,
  • Guohong Li

摘要

This study investigates the effects of tool wear and tool geometry on machining performance during high-speed cutting of TC4 titanium alloy under cryogenic cooling conditions. A finite element model was developed to simulate the influence of flank wear width (VB) and tool nose radius (R) on cutting force, cutting temperature, and residual stress. Selected experiments were conducted to validate the simulation results. The findings reveal that increasing VB and R leads to higher cutting forces, with this trend being more pronounced under cryogenic conditions. When the tool nose radius was 0.2 mm, the cutting temperature decreased by 13.9% compared to dry cutting. At VB = 0.2 mm, cutting force exhibited an “N-shaped” variation with environmental temperature. Cryogenic cooling significantly improved residual stress distribution on the machined surface. At − 142 °C, the range of compressive residual stress increased by 5% and its maximum value improved by 8% relative to − 196 °C. Additionally, a tool life prediction model under low-temperature conditions was developed, providing practical guidance for optimizing TC4 machining processes. These findings contribute to a better understanding of cryogenic machining and support its application in high-performance titanium alloy processing.