EFFECT OF CUTTING CONDITIONS ON THE SERRATED CHIP FORMATION IN HIGH-SPEED CUTTING

Abstract

Titanium alloy Ti6A14V has been widely used in many engineering fields due to its attractive specific strength and corrosion resistance. A deep understanding of the material's machinability is of primary importance. This article investigates the serrated chip formation mechanism of Ti6Al4V alloy under high-speed cutting by finite element analysis. The effect of the cutting conditions on the serrated chip formation is analyzed comprehensively. The study found that when the initial chip thickness becomes small or when the rake angle becomes large, the size of sawtooth decreases and the number of sawtooth increases. The serrated chip morphology is more sensitive to the initial chip thickness. The severe fluctuation of cutting forces is caused by the formation of sawtooth in chipping. To minimize the serrated chipping in high-speed machining, the initial chip thickness is the most important factor to consider.