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Analysis of Microstructure and Chip Formation When Machining Ti-6Al-4V

Lookup NU author(s): Dr Islam Shyha, Dr Dehong Huo



This work is licensed under a Creative Commons Attribution 4.0 International License (CC BY 4.0).


Microstructure and chip formation were evaluated during the step shoulder down-milling of Ti-6Al-4V using a water-miscible vegetable oil-based cutting fluid. Experiments were conducted using the Cut-list fluid supply system previous developed by the authors and a conventional cutting fluid supply system. A thin plastically deformed layer below the machined surface was observed during the metallurgical investigation of the surfaces produced using both systems. Despite noticeable reductions in cutting fluid consumption achieved by Cut-list, no significant disparity was found in microstructural damage. The microstructure of the machined surfaces was strongly affected by cutting speed and fluid flow rate with a discontinuous serrated chip being the principal type. However, increases in cutting fluid flow rate associated with increased cutting speed significantly changed chip morphology where average distance between chip segments increased with cutting speed. Cut-list produced smaller saw-tooth height and larger segmented width, while the transition from aperiodic to periodic serrated chip formation was governed by cutting speed and feed rate. Chip segmentation frequency and shear angle were also sensitive to cutting speed.

Publication metadata

Author(s): Shyha I, Gariani S, El-Sayed M, Huo D

Publication type: Article

Publication status: Published

Journal: Metals

Year: 2018

Volume: 8

Issue: 3

Online publication date: 14/03/2018

Acceptance date: 13/03/2018

Date deposited: 28/03/2018

ISSN (electronic): 2075-4701

Publisher: MDPI


DOI: 10.3390/met8030185


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