Study On The Tool Wear Mechanism And Tool Life For High-Speed Milling Titanium Alloy Ti6Al4V

Ti6A14V are extensively used in aerospace industry because of their excellent properties of high specific strength (strength-to-weight ratio), fracture resistant characteristics, and their exceptional resistance to corrosion. However, Ti6A14V are considered as typical difficult-to-cut materials due to their high temperature strength, high chemical reactivity and its low modulus of elasticity which will lead to rapid tool wear, low machining efficiency, low machining surface quality and high cost. In this paper, some researches were carried out on the fundamental aspects of high speed milling of titanium alloys Ti6A14V, such as the cutting force, cutting temperature, surface integrity. Based on the fundamental study, the comprehensive analysis and study were carried out on tool wear, tool breakage and tool life.1) Cutting force in high speed milling of titanium alloy. The multi-factors orthogonal and single factor experiments were carried out with indexable milling cutter and solid carbide tools. The empirical formula for evaluating the milling force were concluded by means of regression analysis. Range analysis is studied. The variation trend of cutting force along the tool wear was studied.2) Tool life and tool wear mechanism. Multi-factors orthogonal and single factor experiments indexable milling cutter and solid carbide tools were carried out to investigate the tool life. The effects of tool and workpiece material on tool life were also studied, and the empirical equations of tool life were established. Tool wear mechanism and characteristic in high speed milling of titanium alloy were analyzed by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS).3) Variation of surface integrity and chip morphology along tool wear. Based on tool life experiments, variation of surface integrity and chip morphology along tool wear was studied.4) Machining stability in high speed milling of titanium alloy. Based on the dynamic cutting force and dynamics model established, the form error and machining stability of cutting tool and workpieces are analysis were studied. High speed machining stability experiments were conducted with different structure solid carbide tools. Cutting performances were compared of different cutting tools. The influence of cutting parameters to cutting chatter is analyzed.