Effect of milling cutter wear on Ti6Al4V cutting process

When processing Ti6Al4V parts, the machining accuracy is directly affected by the change of cutting force and residual stress from tool wear. Moreover, the fatigue strength, wear resistance, fit stability, and fatigue strength of parts are directly impacted by the change in surface roughness. This research reveals that the Ti6Al4V machining process has the characteristics of severe tool wear and short service life. The effects of milling cutter wear on Ti6Al4V cutting force, surface residual stress, and surface roughness were dissected through milling experiments, which provided the basis for process optimization of Ti6Al4V parts. The specific research findings are as follows: Under constant cutting parameters, the longer the cutting distance of the tool, the greater the cutting force, residual stress, and surface roughness generated, especially when the cutting distance of the tool is in the stage of severe wear, the impact on cutting force, residual stress, and surface roughness is most significant.