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Abstract
Chatter is a deciding factor in milling operations regarding surface integrity and production efficiency. The purpose of this experimental research is to systematically investigate the influence of milling stability on machined surface integrity and fatigue performance of Ti-6Al-4V alloy samples. The surface integrity parameters like roughness, plastic deformation, microhardness, and residual stress were used to evaluate the machined surface quality. The fatigue tests were performed at five tensile stress levels with samples machined under stable, critical stable and unstable (chatter) cutting conditions. The experimental findings show that in comparison with samples produced by stable milling, the machined surface integrity parameters get worse with the increase of chatter amplitude and chatter marks, while fatigue test results show that the average fatigue life of these samples also decreases by about 20 %. The fatigue fracture morphology underscored that multiple fatigue cracks are initiated from the chatter marks on the machined surface. The experimental results provide a quantitative relation between the occurrence of chatter in milling operations and the life expectancy of the corresponding machined parts.
Published Version
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