Abstract
Milling tests were conducted in order to investigate the cutting performances of a binder-less PcBN tool in the machining of Ti-6Al-2Nb-1Ta (α-β type alloy) and Ti-15Mo-5Zr-3Al (β type alloy), which are used as surgical implant materials. In milling of the α-β type alloy, some micro chippings on the rake face of the tool were observed as a typical pattern of tool damage. In the case of the β type alloy, however, there were not only micro chippings on the rake face, but also many micro-flakes on the flank face. The occurrence of micro-flakes on the flank face influenced the structural strength of the cutting edge, and finally caused it to fail. Therefore, the rate of tool damage in milling of the β type alloy was higher than that in milling of the α-β type alloy. Measurement of cutting forces confirmed that in the case of the β type alloy the ratio of the principal cutting force to the thrust cutting force near the point of disengagement of the tool was much higher than that in the cutting process. The force of the principal direction near the point of disengagement was thought to be produced by strong adhesion to the flank face. Also, structure analysis using FEM revealed that the estimated shearing force of the adhesive was sufficient to break the flank face.
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