On the Influence of Work Material Microstructure on Chip Formation, Cutting Forces and Acoustic Emission When Machining Ti-6Al-4V

The influence of heat treatment of work material on chip formation, when machining Ti-6Al-4 V, was studied through microstructural investigation of chips, as well as response on cutting forces and acoustic emission. Three different microstructures were investigated; equiaxed, bimodal and Widmanstätten. It is well known that machining of titanium produces shear localized chips at all industrially practical cutting speeds and feed rates, however there is also a transition from aperiodic to periodic saw- tooth chip formation. The feed rate was varied at constant cutting speed to study this transition from aperiodic to periodic saw-tooth chips in the three microstructures. Face turning cutting tests were used when sensor signals were collected. The results from this investigation stress the importance to consider work material microstructure when studying the chip formation process, and its impact on cutting forces and acoustic emission, when machining Ti-6Al-4 V.