Multi-Objective Optimization of Tool Edge Geometry for Enhanced Cutting Performance in Turning Ti6Al4V

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Manufacturing Technology

Background:

• Conventional cutting tool design relies on trial-and-error or single-objective optimization, failing to address complex coupling mechanisms and multiple performance metrics.
• Existing methods lack coordinated enhancement of cutting force, temperature, and tool wear, limiting overall tool performance and lifespan.

Purpose of the Study:

• To propose and validate a multi-objective optimization framework for cutting tool design integrating joint simulation approaches.
• To achieve coordinated improvements in cutting force, cutting temperature, and tool wear rate through advanced optimization techniques.
• To establish a new paradigm for cutting tool design under complex operational conditions.

Main Methods:

• Development of a finite element model for orthogonal turning, incorporating hyperbolic tangent (TANH) constitutive and variable coefficient friction models.
• Comparative analysis of cutting performance for four micro-groove configurations.
• Parametric modeling coupled with simulation-data interaction for multi-objective optimization using the Non-dominated Sorting Genetic Algorithm II (NSGA-II).
• Experimental validation of optimized tools manufactured via powder metallurgy.

Main Results:

• Optimized tools demonstrated a 19.3% reduction in cutting force, a 14.2% decrease in cutting temperature, and a 33.3% increase in tool life compared to baseline tools.
• Enhanced chip control observed with an 11.4% reduction in chip curl radius.
• Diminished oxidation/adhesive wear and superior surface finish were achieved, indicating improved durability and quality.

Conclusions:

• The proposed multi-objective optimization framework effectively overcomes limitations of conventional single-parameter optimization methods.
• The methodology substantially improves comprehensive tool performance, offering a significant advancement in cutting tool design.
• This study provides a reference paradigm for designing cutting tools optimized for complex operational conditions and multiple performance criteria.