Study of chip adhesion behavior in titanium alloy dry milling process based on image extraction technology

This paper studied the chip adhesion behavior of titanium alloy Ti-6Al-4 V under different cutting parameters, and the image extraction technology was used to quantify the surface chip adhesion rate. The correlation among cutting speed, feed rate, radial cutting width, and machined surface chip adhesion rate was discussed. Moreover, the effect of these different parameters on temperature was investigated to analyze further the correlation between cutting temperature and chip adhesion. In addition, factors such as tool wear and the mechanical vibration are ignored in the experiment. The results show that chip adhesion occurs in almost all machining conditions, both down-milling and up-milling. With the same cutting parameters, the chip adhesion rate after up-milling is much higher than that after down-milling. Furthermore, cutting speed is one of the most critical factors affecting the adhesion of chips. Especially at a high cutting speed of 151 m/min, the chip adhesion rate of up-milling is about 18 times that of down-milling. It was also found that the surface roughness and cutting temperature values of down-milling are lower than those of up-milling. This study provides an essential reference for the suppression of chip adhesion during the milling of titanium alloys.