Investigation the effect of tool geometry in micro turning process

Micro-turning is very similar to conventional turning, but is a cutting operation in which the tool geometry effect is more important. For this reason, the cutting geometry and cutting parameters used in micro turning must be carefully selected. In this study, nose radius and edge radius differences in micro turning process; the effects of cutting forces, under-surface residual stresses, tool stresses and surface roughness were investigated. For this purpose, a special test setup is used which can cut at high speeds and high precision. Ti6Al4V alloy as workpiece and two different cutting tool geometry are used. In the study, numerical modeling commercial software, DEFORM 2D / 3D software was used. The material model used was confirmed by 2D and 3D analysis and solutions were made for different edge and nose radius. Increased edge and nose radius also increase cutting forces. If the nose radius is greater than the depth of cut, as the nose radius increases, the cutting forces decrease against expectation. The compressive stresses under the surface can be returned to the tensile stress by increasing the edge radius. Surface roughness increased as the feed decreased after a critical value.