Tool wear behaviors and corresponding machined surface topography during high-speed machining of Ti-6Al-4V with fine grain tools

Rapid tool wear of machining Ti-6A1-4V causes the surface deterioration and manufacturing cost increasing. This work studied tool wear behaviors and machined surface topography during high-speed machining of Ti-6A1-4V. Firstly, detailed wear of tool rake face and flank face were studied in wear topography and chemical elements. Tool rake face was related to the combined effects of adhesion-diffusion-abrasion wear, while predominant wear mechanism of flank face was adhesion-abrasion. The cutting edge chippings and deformation destroyed the structure and strength of cutting tools. Secondly, the effects of tool wear on the corresponding surface topography were evaluated in surface roughness and defects. The tool flank wear should be controlled in less than 0.2 mm from the viewpoint of getting better surface topography.