Shear displacement and actual strain during chip segmentation when cutting aerospace alloy Ti-5553

Ti-5553 (Ti-5Al-5Mo-5V-3Cr-0.5Fe) is a recently developed near-β Ti alloy with potential application in structural components of aircrafts. However, Ti-5553 has shown poorer machinability than other Ti alloys. The objectives of the present study are to understand the chip formation mechanism, calculate the actual strain within the segments of chip and its narrow shear bands, and to evaluate the effect of cutting condition on the shear strain. Cutting tests were conducted under three levels of cutting speeds and feeds, and the chips micrographs were collected and analyzed. It was found that the cutting conditions have a significant impact on the shear strain.