Power consumption and tool wear assessment when machining titanium alloys

Titanium alloys are of interest for aerospace industries due to their high strength to weight ratio, outstanding corrosion and erosion properties and ability to operate at higher temperature. They are classified as difficult to cut materials because of their low thermal conductivity, high chemical reactivity and high strength at elevated temperature. The machinability rating of titanium alloys is low compared to other materials from many aspects. This study focuses on studying the cutting tool wear and power consumption when machining Titanium alloys under different cutting conditions. Design of experiments was used to develop a test matrix that cover the range of cutting conditions recommended for machining titanium alloys. Cutting forces, power consumption, tool wear and surface roughness were measured and analyzed. Tool wear mechanisms were also studied using scanning electron microscopy.