Chip Formation in High-Speed Milling of Titanium Alloy with PCD Tools

Abstract:

This paper presents a detailed analysis of chip morphology through an experimental study of high-speed milling of Ti-6Al-4V alloy with PCD tools. Milling tests were conducted for cutting speed range from 125 m/min to 2000 m/min with water-soluble cutting fluid. The collected chips were firstly examined with a digital cameras and the free surface of the chips was analyzed by a scanning electron microscope (SEM). Geographical parameters of chip morphologies were described in saw-tooth/lamella frequency on the free surface and chip width. Experimental results show that the variation of chips in high-speed end milling of Ti-6Al-4V alloy is as follows, long and straight-shaped → spiral-shaped → curly-shaped → irregular-shaped. The free surface of chips exhibits saw-tooth lamella structures. The lamella becomes clearer and more obvious at higher cutting speeds. Within the same measurement distance, there is a sharp decrease in the lamella number within same measuring range. This should be attributed to the enhancement of the thermal mechanical coupled field applied to the chip formation processes.

• Periodical: Materials Science Forum (Volumes 800-801)
• Pages: 150-154
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.800-801.150
• Online since: July 2014
• Authors: An Hai Li*, Jun Zhao, Hong Guo Zheng, Yong Hong Lu
• Keywords: Chip Morphology, High-Speed Machining, Saw-Tooth Chip, Titanium Alloy

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DOI: 10.1016/s0007-8506(07)60534-4

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