Impact of active chip breakers on Ti6Al4V turning process

Continuous chips generated during Ti-6Al-4V turning often entangle tools and workpieces, risking surface damage and tool failure, thereby compromising machining safety. This study proposes an active chip-breaking device installed above the tool rake face. Three chip breaker designs were tested: Type A (hook-shaped, biased toward the unprocessed surface), Type B (biased toward the machined surface), and Type C (straight-tooth). Cutting tests showed that commercial grooved inserts produced unbroken chips, while all three chip breakers enabled reliable chip fragmentation and ejection, preventing entanglement and reducing cutting temperatures. Increasing rotational speed reduced chip length, but excessive speed (8000 rpm) caused chip residue on machined surfaces. Optimal performance occurred with Type A at 6000 rpm, achieving a 14.42% reduction in surface roughness compared to ordinary turning. The results demonstrate that active chip breakers effectively mitigate Ti-6Al-4V machining challenges, with design and speed parameters critically influencing chip control and surface quality.