Microchannel engrooved carbide tool rake: a feasibility study for machining Ti-6Al-4V

Improving machinability of various difficult-to-cut materials has become essential in recent years. Out of several parameters, enhancing the delivery method of cutting fluids enhances machinability. Several researchers have previously found that utilising the Minimum Quantity Lubrication technique for cutting fluid delivery has had beneficial effects. Nevertheless, a significantly persisting problem is the ineffective penetration of cutting fluid in certain zones in the chip-tool interface. Microchannel fabrication on cutting tools may help cutting fluids penetrate the chip-tool heat generation zone effectively. However, micro-channelling may also increase the stress concentration on the cutting tool, thus it may promote catastrophic failure. This article aims to discuss the effect of creating a single microchannel on tool rake surfaces to improve the penetrability of the cutting fluid while also determining the change in the tool’s stability. Diversifying the shape of the microchannel by keeping its width unwavering, and changing its nearness from the principle cutting edge, simulations were performed. Further investigations reveal that incorporating microchannels can have a positive impact on cutting fluid delivery without sabotaging the tool’s strength. This inadvertently may help in effective cooling, lubrication and protection of the cutting tool.