Analysis on the correlation between cutting signals and surface quality in milling process of Ti-6Al-4V

The application of Titanium alloys has gradually increased because of its superior thermal and mechanical properties. Ti-alloys have higher strength and light weight compared to steel. However, Ti-alloys have poor machineability due to their low thermal conductivity and stiffness. As the machining proceeds, the tool wear is accelerated and abnormal conditions such as chipping and fracture of cutting edge occur. This paper presents an investigation on the effect of tool wear on surface quality in milling process of Ti-6Al-4V. The cutting force signals and acceleration signals are acquired during the machining experiments. And the machined surface is observed to check tool marks and surface roughness. The experiments are conducted until the milling tool is completely worn out. The changes of cutting force, acceleration, and surface condition according to tool wear are analyzed in machining process.