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Impact of active chip breakers on Ti6Al4V turning process.

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Title: Impact of active chip breakers on Ti6Al4V turning process.
Authors: Shu, Shengrong1 (AUTHOR) shushengrong201@163.com, Hu, Zuchao1 (AUTHOR), Li, Xuewei1 (AUTHOR), Huang, Quanfeng1 (AUTHOR)
Source: Materials & Manufacturing Processes. 2025, Vol. 40 Issue 8, p1123-1132. 10p.
Subjects: Surface roughness, Conformance testing, Quality control, Workpieces, Speed, Cutting tools
Abstract: Continuous chips generated during Ti-6Al-4V turning often entangle tools and workpieces, risking surface damage and tool failure, thereby compromising machining safety. This study proposes an active chip-breaking device installed above the tool rake face. Three chip breaker designs were tested: Type A (hook-shaped, biased toward the unprocessed surface), Type B (biased toward the machined surface), and Type C (straight-tooth). Cutting tests showed that commercial grooved inserts produced unbroken chips, while all three chip breakers enabled reliable chip fragmentation and ejection, preventing entanglement and reducing cutting temperatures. Increasing rotational speed reduced chip length, but excessive speed (8000 rpm) caused chip residue on machined surfaces. Optimal performance occurred with Type A at 6000 rpm, achieving a 14.42% reduction in surface roughness compared to ordinary turning. The results demonstrate that active chip breakers effectively mitigate Ti-6Al-4V machining challenges, with design and speed parameters critically influencing chip control and surface quality. [ABSTRACT FROM AUTHOR]
Copyright of Materials & Manufacturing Processes is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
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  Data: Impact of active chip breakers on Ti6Al4V turning process.
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  Data: <searchLink fieldCode="JN" term="%22Materials+%26+Manufacturing+Processes%22">Materials & Manufacturing Processes</searchLink>. 2025, Vol. 40 Issue 8, p1123-1132. 10p.
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  Data: <searchLink fieldCode="DE" term="%22Surface+roughness%22">Surface roughness</searchLink><br /><searchLink fieldCode="DE" term="%22Conformance+testing%22">Conformance testing</searchLink><br /><searchLink fieldCode="DE" term="%22Quality+control%22">Quality control</searchLink><br /><searchLink fieldCode="DE" term="%22Workpieces%22">Workpieces</searchLink><br /><searchLink fieldCode="DE" term="%22Speed%22">Speed</searchLink><br /><searchLink fieldCode="DE" term="%22Cutting+tools%22">Cutting tools</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Continuous chips generated during Ti-6Al-4V turning often entangle tools and workpieces, risking surface damage and tool failure, thereby compromising machining safety. This study proposes an active chip-breaking device installed above the tool rake face. Three chip breaker designs were tested: Type A (hook-shaped, biased toward the unprocessed surface), Type B (biased toward the machined surface), and Type C (straight-tooth). Cutting tests showed that commercial grooved inserts produced unbroken chips, while all three chip breakers enabled reliable chip fragmentation and ejection, preventing entanglement and reducing cutting temperatures. Increasing rotational speed reduced chip length, but excessive speed (8000 rpm) caused chip residue on machined surfaces. Optimal performance occurred with Type A at 6000 rpm, achieving a 14.42% reduction in surface roughness compared to ordinary turning. The results demonstrate that active chip breakers effectively mitigate Ti-6Al-4V machining challenges, with design and speed parameters critically influencing chip control and surface quality. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials & Manufacturing Processes is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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      – Type: doi
        Value: 10.1080/10426914.2025.2487270
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      – Code: eng
        Text: English
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        PageCount: 10
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      – SubjectFull: Surface roughness
        Type: general
      – SubjectFull: Conformance testing
        Type: general
      – SubjectFull: Quality control
        Type: general
      – SubjectFull: Workpieces
        Type: general
      – SubjectFull: Speed
        Type: general
      – SubjectFull: Cutting tools
        Type: general
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      – TitleFull: Impact of active chip breakers on Ti6Al4V turning process.
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            NameFull: Shu, Shengrong
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            NameFull: Hu, Zuchao
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            NameFull: Li, Xuewei
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            NameFull: Huang, Quanfeng
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          Dates:
            – D: 01
              M: 06
              Text: 2025
              Type: published
              Y: 2025
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            – TitleFull: Materials & Manufacturing Processes
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