Compression deformation in the primary zone during the high-speed cutting of titanium alloy Ti-6Al-4V

The mechanism of serrated-chip formation is a basic theoretical foundation for metal cutting. Much research has concentrated on the shear formation characteristics of serrated-chip formation. However, compression deformation has not been proposed to elucidate serrated-chip deformation within the primary zone. This paper proposes a computational model considering compression deformation in the primary zone. Compression deformation characteristics are obtained by combining the model with the results of a high-speed orthogonal cutting experiment. In a high-speed orthogonal cutting experiment on Ti-6Al-4V at cutting speeds of 10–160 m/min and feed rates of 0.07–0.11 mm/r, the compression stress (1134–1600 MPa) decreased with the cutting speed and feed rate. The compression strain (0.10–0.22) and strain rate (0.09 × 104/s–0.75 × 104/s) increased with the cutting speed and decreased with the feed rate. The temperature of the primary zone (272.3–417.2 °C) increased with the cutting speed and feed rate. © Springer-Verlag London Ltd., part of Springer Nature 2019.