Thermal process signature in machining of Ti-6Al-4V with worn tools

Orthogonal machining experiments to calibrate thermal process signature predictions due to the effects of tool wear, feed, and cutting speed effects were conducted. Two flank wear conditions of 0 and 300 microns, three feeds of 0.005, 0.05, and 0.1 mm/rev, and cutting speeds from 10 to 200 m/min were evaluated. Cutting forces and infrared thermal fields were leveraged to evaluate thermal process signatures in terms of thermal layer depth. Correlation between the proposed model and experimental data was within 10%, suggesting that a hybrid approach of physics-based and data-driven modeling may help to reliably avoid thermal damage.