A Study on the High Speed Face Milling of Ti-6Al-4V Alloy

Abstract

This paper is concerned with the experimental and numerical study of the high speed face milling of Ti-6Al-4V titanium alloy. Machining is carried out by uncoated carbide and polycrystalline diamond cutters in the presence of an abundant supply of coolant. Experimental analysis is conducted in terms of cutting forces, chip morphology, surface integrity and tool wear. The experimental analysis is supplemented by simulations from the finite element analysis where needed. The highest cutting speed realized for both the cutting tool materials is 600 sfpm with the diamond cutter operating at feeds lower than that for carbide. Good surface integrity in terms of residual stress and surface finish is achieved under the machining conditions used with limited tool wear. Residual stresses imparted to the machined surface are compressive with the diamond tool yielding higher values and are the most sensitive to feed. Tool wear patterns are described in terms of various cutting conditions.