Methodology to Determine Friction in Orthogonal Cutting With Application to Machining Titanium and Nickel Based Alloys

Friction plays a very important role in machining titanium and nickel alloys. It is the source for the high amount of heat generation, and as a result, the excessive tool wear during machining these materials. The worn tool is known to create lower surface qualities with tensile surface residual stresses and machine-induced hardening at the surface, as well as high surface roughness. It is essential to create a method to determine how and to what extent the friction is built up on the tool. This study facilitates a determination methodology to estimate the friction coefficients between the tool and the chip on the rake face, as well as the tool and the workpiece on the flank face of the tool. The results are validated with experimental results from the titanium alloy Ti-6Al-4V and the nickel alloy IN-100.