Investigation of surface topography and its deterioration resulting from tool wear evolution when dry turning of titanium alloy Ti-6Al-4V

Tool wear inevitably occurs in dry cutting titanium alloy Ti-6Al-4V, and it causes the machined surface deterioration. This research aimed to synthetically investigate surface topography characterization with emphasizing tool flank wear effects in dry turning titanium alloy Ti-6Al-4V. The surface analysis techniques including three dimension (3D) surface parameters and surface defects were implemented to assess surface topographies by using confocal laser scanning microscope and scanning electron microscope. A detailed comparison of 3D surface topography in terms of amplitude, spatial, hybrid, functional, and volume parameters was analyzed under various tool wear stages. The undesirable surface defects, such as feed marks, plowing grooves, side flow, plastic flow, and adhered material particles, surface tearing, surface burning, scratch marks were discussed on the basis of tool wear patterns and additional thermo-mechanical loads. Experimental findings indicated that a good correlation was presented between surface topography evolution and tool wear effects.