Tool wear mechanisms involved in crater formation on uncoated carbide tool when machining Ti6Al4V alloy

When machining titanium alloys at cutting speeds higher than 60 m/min using cemented carbide cutting tools, the tool wears out rapidly. With the ever-increasing use of titanium alloys, it is essential to address this issue of rapid tool wear in order to reduce manufacturing costs. Therefore, the intention of this study was to investigate all possible tool wear mechanisms involved when using uncoated carbide cutting tools to machine Ti6Al4V titanium alloy at a cutting speed of 150 m/min under dry cutting conditions. Adhesion, diffusion, attrition, and abrasion were found to be the mechanisms associated with the cratering of the rake surface of the cutting tool. The plastic deformation of the cutting edge was also noticed which resulted in weakening of the rake surface and clear evidence has been presented. Based on this evidence, the process of the formation of the crater wear has been described in detail.