The objective of this work is to identify some of the tool wear mechanisms at the material level for the machining of titanium and to provide some understanding of these mechanisms for use in physics based tool wear models. Turning experiments were conducted at cutting speeds of 61m/min, 91m/min, and 122m/min on Ti-6Al-4V, an alloy of titanium, using two different grades of tungsten carbide cutting inserts and one grade of polycrystalline diamond inserts. Three-dimensional wear data and two-dimensional wear profiles of the rake face were generated using Confocal Laser Scanning Microscopy to quantify the tool wear mechanisms. Additionally, the microstructure of the deformed work material (chip) and un-deformed parent material (work piece) were studied using Orientation Imaging Microscopy (OIM). Observations from tool wear studies on the PCD inserts revealed the presence of two fundamentally different wear mechanisms operating at the different cutting speeds. Microstructural analyses of the chip and the work material showed phase dependent tool wear mechanisms for machining titanium. There is a high likelihood of phase change occurring in the work material during machining, with a transformation from the alpha phase to the beta phase. The observed dramatic increase in wear is attributed to a combination of increased diffusivity in the beta phase of the titanium alloy in conjunction with a higher degree of recrystallization of the prior beta phase upon cooling. Results of other observations such as the influence of carbide grain size on tool wear are also discussed.
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