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.

由于Ti6Al4V材料的可加工性较差，刀具在高速侧铣过程中极易发生后刀面磨损，从而降低刀具寿命和工件表面完整性。此外，现有文献缺乏预测Ti6Al4V侧铣端铣刀后刀面磨损的有效方法，从而难以提高整个工艺的生产率。为此，在本研究中，基于三种主要机制构建了后刀面磨损预测模型：磨粒磨损、粘着磨损和扩散磨损。随后，建立了立铣刀后刀面磨损区的法向应力模型和温度场模型。最后将这两个模型结合到后刀面磨损模型中，得到磨损面宽度的变化率，这被视为评估所提出的侧铣刀后刀面磨损预测模型可靠性的标准。发现预测结果与实验结果非常吻合，验证了所提出模型的高预测精度。总体而言，该模型可为合理选择刀具几何形状和切削参数提供有用的理论依据。