Formation Mechanism and Morphology Observation of Chips in High-Speed Milling of Titanium Alloy

Abstract

The study of chip morphology during high-speed milling is crucial in determining processing quality, but the relationship between chip formation mechanisms and process parameters in titanium alloy high-speed machining has been a difficult issue. This paper investigates milling force and temperature variation, as well as chip morphology and surface quality after milling to improve workpiece surface quality and machining efficiency and provide guidance on selecting milling parameters. Factorial analysis confirms that milling speed worsens the serrated layer of chips. In addition, the experiment confirms the influence of tool rake angle on shear strain in the milling zone, the impact of rotational speed on tool wear, and the effect of tool wear on chip morphology. The results show that increasing milling speed worsens chip serration and increases tool wear.