The impact of machining parameters and tool nomenclature on chip morphology and tool wear characterisation in the Ti6Al4V superalloy

In this work, we report the influence of tool nose radius and machining parameters on the superalloy Ti6Al4V machined in a CNC lathe machine. The nose radius of the tool and machining parameters are considered as influencing parameters in the machining of the superalloy Ti6Al4V. Here, tools of 0.4 mm and 0.8 mm nose radius CNC lathe carbide inserts are being used as tools for machining operations. The chips formed at different speeds, and the nose radius of inserts is collected and tested for studying microstructural properties by taking high-resolution images in a scanning electron microscope (SEM). The obtained results are analyzed with the help of these SEM images. The surface morphology and microstructure changes are being studied. The results will help in identifying optimal parameters for minimizing tool wear and surface defects. From the study, it is observed that the cutting force decreases with increased speed of cutting. For a lower speed of cutting (1000 and 1500 rpm) and radius of nose (0.4 mm), a drained surface has been observed above the rake surface during machining. Further, an increase in the nose radius leads to greater deformation in the plastic region and the formation of chip morphology. Uncertainty of 5.64% and 5.86% has been reported for the 100 μm and 50 μm elements. Smaller particle sizes (50 μm) generally reduce measurement uncertainty due to improved homogeneity, while larger particles (100 μm) introduce higher variability.