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Investigation on tool wear and tool life prediction in micro-milling of Ti-6Al-4V

Lookup NU author(s): Amin Dadgari, Dr Dehong Huo, Dr David Swailes



This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License (CC BY-NC-ND).


© 2018, Editorial Office of Nanotechnology and Precision Engineering. All right reserved. Short tool life and rapid tool wear in micromachining of hard-to-machine materials remain a barrier to the process being economically viable. In this study, standard procedures and conditions set by the ISO for tool life testing in milling were used to analyze the wear of tungsten carbide micro-end-milling tools through slot milling conducted on titanium alloy Ti-6Al-4V. Tool wear was characterized by flank wear rate, cutting-edge radius change, and tool volumetric change. The effect of machining parameters, such as cutting speed and feedrate, on tool wear was investigated with reference to surface roughness and geometric accuracy of the finished workpiece. Experimental data indicate different modes of tool wear throughout machining, where nonuniform flank wear and abrasive wear are the dominant wear modes. High cutting speed and low feedrate can reduce the tool wear rate and improve the tool life during micromachining.However, the low feedrate enhances the plowing effect on the cutting zone, resulting in reduced surface quality and leading to burr formation and premature tool failure. This study concludes with a proposal of tool rejection criteria for micro-milling of Ti-6Al-4V.

Publication metadata

Author(s): Dadgari A, Huo D, Swailes D

Publication type: Article

Publication status: Published

Journal: Nami Jishu yu Jingmi Gongcheng/Nanotechnology and Precision Engineering

Year: 2018

Volume: 1

Issue: 4

Pages: 218-225

Print publication date: 01/12/2018

Online publication date: 03/01/2019

Acceptance date: 02/04/2016

Date deposited: 23/04/2019

ISSN (print): 1672-6030

ISSN (electronic): 2589-5540

Publisher: Tianjin University


DOI: 10.1016/j.npe.2018.12.005


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Funder referenceFunder name
Engineering and Physical Sciences Research Council (EP/M020657/1)