On the effect of regrinding cutting tools for high performance milling of titanium alloys

The main challenges in high performance milling of difficult-to-machine metals are embedded in the development of innovative machining methods and cutting strategies. The aim is to reduce cycle time, resources and cost while maintaining or enhancing the machined product’s quality and performance. This will assist to increase both productivity and profitability. Many of the same material properties that make titanium alloys attractive for various industrial applications also contribute to its machining challenges. Tooling cost is one of the significant input costs associated with the cutting of titanium, and in order to reduce this, regrinding is used to extend the tool life of solid carbide end mill cutting tools. In an endeavour to increase the competitiveness of titanium machining companies, the effect of regrinding cutting tools on high performance milling of titanium alloys is studied. The research objectives include investigation into the effect of regrinding on the transition of tool wear phenomena, tool life tendency, part quality, cost, production rate and the high efficiency cutting speed range. It was found that the cost per machined volume of the reground cutting tools was significantly lower than that of the new cutting tools. This tendency increased with higher material removal rates. It was possible to recover more than 60 % of the original tool life using regrinding at a cost of 9 % the original purchase price.