Modelling methods for the transient temperature field of wear land on the flank of end mills have been proposed to address the challenges of inaccurate prediction in the temperature field of end mills during the high-speed peripheral milling of Ti6Al4V that is a titanium alloy. A transient temperature rise model of wear land on the flank of end mills was constructed under the influence of heat sources in the primary shearing zone (PSZ), rake-chip zone (RCZ), flank-workpiece zone (FWZ), and dissipating heat source. Then the transient temperature field model of wear land on the flank of end mills was constructed. Finally, the transient temperature field model of wear land on the flank of end mills was constructed. Comparison of simulation result and experimental data verified the accuracy of the model. In sum, the proposed model may provide a temperature model support for future studies of flank wear rate in end mill modeling.

Due to the poor machinability of Ti6Al4V material, the cutting tool can easily suffer flank wear during the process of high-speed side milling, which reduces the tool life as well as the surface integrity of workpiece. Further, an effective method for predicting the flank wear of end mill during side milling of Ti6Al4V is lacking in the existing literature, which makes it difficult to improve the productivity of the overall process. To this end, in this study, a flank wear prediction model is constructed based on three main mechanisms: abrasive wear, adhesive wear, and diffusive wear. Subsequently, a normal stress model and temperature field model of wear land on the flank of end mill are established. Finally, these two models are incorporated in the flank wear model to obtain the variation rate of wear land width, which is regarded as a criterion to evaluate the reliability of the proposed flank wear prediction model of side mill. The prediction results are found to be in excellent agreement with the experimental results, which verifies the high prediction accuracy of the proposed model. Overall, this model can serve as a useful theoretical basis for the rational selection of tool geometry and cutting parameters.

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