Tool Wear Progression and its Effect on Energy Consumption in Turning of Titanium Alloy (Ti-6Al-4V)

To achieve greater productivity, titanium alloy requires cutting at higher speeds (above 100 m min−1) that affects the tool life and energy consumption during the machining process. This research work correlates the wear progression and Specific Cutting Energy (SCE) in turning Ti-6Al-4V alloy using H13 tools (uncoated carbide) in dry conditions from low to high cutting speeds. Cutting condition employed in this study were selected from published wear map developed for titanium (Ti-6Al-4V alloy) with the same tool. Flank wear growth of the tool has been investigated at different length of cuts in correlation with the SCE under different cutting conditions. The useful tool life was found to be shorter at high-speed machining conditions, thus the end of useful tool life criteria (ISO 3685) was reached at a much shorter length of cuts as compared to low-speed machining conditions. The cutting conditions corresponding to high wear rate also resulted in high SCE. Finally, SCE and wear have been related by a linear relationship that can be used to monitor wear and/or SCE utilization during machining. The results help in the selection of appropriate cutting conditions that will enhance the tool life and minimize SCE consumption during machining titanium alloy.