Investigation of the Impact of High-Speed Machining in the Milling Process of Titanium Alloy on Tool Wear, Surface Layer Properties, and Fatigue Life of the Machined Object

Abstract

This article presents the results of experimental research on the effect of high-speed machining (HSM) in the milling process on the tool wear, surface layer properties, and fatigue life of objects made of Ti-6Al-4V titanium alloy. Titanium alloys are widely used in many industries due to their high strength-to-density ratio, corrosion resistance, and resistance to dynamic loads. The experiment was conducted on a vertical three-axis machining centre, Avia VMC800HS. The influence of increased cutting speeds on the average values and amplitudes of the total cutting force components and the surface roughness of the machined workpiece was determined. Variable cutting speeds vc = 70; 130; 190; 250; 310 m/min were applied. The impact of HSM on machinability indicators, such as the microhardness of the surface layer, the distribution of residual stresses, and the fatigue life of the samples after milling, was analysed. The thickness of the hardened layer varied from 20 to 28 micrometres. The maximum compressive residual stress Ϭm = 190 MPa was achieved at the speed of vc = 190 m/min. A significant influence of increased cutting speeds on tool wear was demonstrated. The longest tool life (t = 70 min) was obtained for low cutting speeds (conventional) vc = 70 m/min.