Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti2AlNb intermetallic alloys

Ti₂AlNb intermetallic alloys, which belong to the titanium aluminum (TiAl) family, are currently being extensively researched and promoted in the aerospace industry because of their exceptional properties, including low density, high-temperature strength, and excellent oxidation resistance. However, the excellent fracture toughness of the material leads to the formation of surface defects during machining, thereby affecting the quality of the machined surface. In this study, Ti₂AlNb intermetallic alloys were subjected to side-milling trials to investigate the influence of tool coating and tool wear on both the machined surface quality and chip morphology. Specifically, the tool life, machined surface roughness, surface morphology, surface defects, and chip morphology were investigated in detail. The results indicated that the tool coating provided a protective effect, resulting in a threefold increase in the service life of the coated end mill compared to that of the uncoated one. A coated end mill yields a superior machined surface topography, as evidenced by reduced roughness and a more consistent morphology. Tool wear has a significant effect on the morphology of machined surfaces. The occurrence of material debris and feed marks became increasingly severe as the tool wore off. The chip morphology was not significantly affected by the tool coating. However, tool wear results in severe tearing along the chip edge, obvious plastic flow on the non-free surface, and a distinct lamellar structure on the free surface.