Numerical Investigation of Dislocation Density and Grain Size Evolution in Orthogonal Cutting of Pure Titanium Using Microgrooved Cutting Tools

In this paper, a coupled Eulerian-Lagrangian (CEL) finite element model is developed based on FEM software package Abaqus to solve the evolution of the dislocation density and grain size simultaneously. This validated CEL FEM model is then utilized to investigate the effects of microgrooved cutting tools on the evolution of dislocation density and grain size in orthogonal cutting of commercially pure titanium (CP Ti). Microgrooved cutting tools are cemented carbide (WC/Co) cutting inserts with microgrooves on the rake face. The effects of microgroove width and microgroove convex width are investigated in terms of cutting force, chip morphology, dislocation density, and grain size. It is concluded that this CEL FEM model can capture the essential features of orthogonal cutting of commercially pure titanium (CP Ti) alloy using microgrooved cutting tools. It is also concluded that microgroove width and convex width have substantial influence on the dislocation density profiles and grain size profiles along the depth from the machined surface and the tool-chip interface, respectively. This conclusion provides insightful guidance for altering the surface integrity of the machined surface based on needs.