Chip formation in high speed milling of Ti-6Al-4V alloy under nitrogen-oil-mist

High speed milling experiments using nitrogen-oil-mist as the cutting medium were carried out to investigate the characteristics of chip formation for Ti-6Al-4V alloy.Within the range of conditions employed(cutting speed,vc=190-300 m/min;cutting depth of axial,ap=5,7 mm),saw-tooth chips were produced in these experiments.During the macro and micro analysis of the Ti-6Al-4V chips,an optical microscope and a scanning electron microscope(SEM)were used to study the microstructure and the morphology of the chips,and the X-ray photoelectron spectroscopy(XPS)was employed for chemical analysis.Comparisons were made to study the influence of different cutting media(nitrogen-oil-mist,air-oil-mist and dry cutting condition)on chip formation.Results indicate that cutting media have significant effects on chip formation.Nitrogen-oil-mist is more suitable for improving the contact condition at chip-tool interface and increasing the tool life in high speed milling of Ti-6Al-4V alloy than air-oil-mist and dry cutting.