Analysis of tool wear in ultrasonically assisted turning of beta-Ti-15V-3Al-3Cr-3Sn alloy

An extremely high tool wear rate in the machining of titanium alloys (Ti alloys) is one of the major reasons limiting the use of conventional machining processes for the components made of these alloys. The machinability of a -Ti-15V-3Al-3Cr-3Sn (Ti- 15333) alloy can be signi cantly improved using an advanced machining technique known as Ultrasonically Assisted Turning (UAT). The key mechanism of tool wear associated with UAT of Ti-15333 alloy is still unknown. The present study begins to address this issue by examining wear behaviour of two di erent types of cutting inserts using UAT and Conventional Turning (CT) of Ti-15333 alloy. Tool wear was measured using 3D optical microscope and the composition of the Built-Up Edge (BUE) on the worn tools was analysed with scanning electron microscopy. A robust experimental methodology was developed, which provided repeatable and statistically reliable tool wear results. The KC5510 cutting inserts demonstrated better tool-life in UAT when compared to CP-500 inserts.