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This paper focuses on the influence of cutting tool edge geometry, cutting speed and feed rate on the tool performance and workpiece’s surface integrity in dry turning of Ti-6Al-4V alloy using PCBN inserts. The parameters evaluated are tool life, wear rate, wear mechanisms, surface roughness and subsurface microstructure alterations. The rate of wear growth of the insert was assessed by progressive flank wear using optical microscope by taking photographs after certain length of cut. The wear mechanism at the end of tool life was investigated in detail using scanning electron microscope (SEM) and EDAX analysis. The results show, by increasing the cutting speed and feed rate resulted in tool life reduction. Cutting with honed edge insert at cutting speed of 180 m/min has shown very little wear, even after 20 min of cutting. The honed insert proved less sensitive to increases in feed rate than the chamfered insert. In general the honed insert showed a significant improvement in tool life. All inserts failed due to attrition wear and adhesion. No flank notch wear was observed, but some crater wear occurred at the chamfer land. Microstructure alteration was not found when machining using the different edge geometry. In these trials, the subsurface micro structural deformations in the direction of cutting were deformed grain boundaries and elongation of grains. Chip smearing and debris on the surface was also found.

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