Tool wear mechanisms and micro-channels quality in micro-machining of Ti-6Al-4V alloy using the Ti(C7N3)-based cermet micro-mills

The cutting mechanism changes back and forth between ploughing-dominated and shearing-dominated in micro-milling of channel. This study was to research the tool wear mechanisms and micro-channels quality using the Ti(C7N3)-based cermet micro-mills in machining Ti-6Al-4V alloy. Tool wear mechanisms contained the adhesive wear, micro-chipping, oxidative wear, flank wear and diffusion wear. However, the abrasive wear was not discovered, which was a distinct wear mechanism with macro-milling. The higher feed rate induced the tool tip temperature and increased workpiece temperature, and the maximum tool tip temperature was 123.6 degrees C. Moreover, Tool wear of the micro-mill was improved, and the micro-channels quality also enhanced under the feed rate of 1 mu m/flute.