With the growing popularity of titanium, tool designers are coming up with unique solutions for improving the machinability of titanium. Advanced materials, like heat-resistant titanium aluminum nitride (TiAlN) or titanium carbo-nitride (TiCN) coated tooling, can extend tool lifetimes. Meanwhile tooling with uneven spacing between cutting edges can disrupt the constructive interference that leads to tool chatter.

There is no singular property that makes titanium harder to machine than other materials. Instead, a combination of different properties work together to make most conventional machining tactics ineffective. By understanding what these challenges are, metallurgists and machinists can find solutions processing solutions that lead to high-quality machined titanium parts.

Just remember that titanium alloys require careful machining, which must be carried out by trained experts. In contrast to free machining metals like Brass C360 or Steel SS416, working with titanium requires expertise, patience, and the correct tools.

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Due to the increasing demand for titanium, several machinable grades have been developed in the industry. They are differentiated by the percentages of pure titanium and other elements they contain, including elements like oxygen, palladium, nickel, or molybdenum.

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This article will help you understand the challenges of machining titanium and some tips on how to machine titanium more effectively. We’ve also assembled a list of some of the best titanium grades for machining applications.

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Overall, machinists should choose high-quality tools designed for use with titanium, and they should frequently inspect and replace dull tools. Also consider using a smaller diameter tool with a larger number of cutting edges. This helps to maintain metal removal rates while reducing heat accumulation.

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Titanium is an amazing material with some truly outstanding properties. It has a very high strength, is lightweight, is resistant to corrosion and chemicals, and can even maintain its strength when exposed to incredibly high temperatures.

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With titanium it’s also important to be very intentional about feed rates, spindle speeds, and chip loads. This means preventing excessive strain on tooling and equipment while also avoiding lingering in the same location for too long. It’s also worth evaluating whether a different cutting approach, like increasing axial cut depth while reducing radial engagement, could improve cutting efficiency and reduce machining temperatures.

Lastly, depending on the design of the part, the elastic behavior of titanium can also make unsupported portions of a workpiece elastically deform out of position. The part bends away from the forces created by cutting tools, then returns to its normal position after the cutting tool passes, creating final parts that are out of tolerance.

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As if that wasn’t enough, the low modulus of elasticity of titanium compared to its high strength makes it a “gummy” material to machine and can lead to severe chatter. This can result in galling of cut titanium, which adheres to tooling. Additionally, chatter and titanium’s springback effect at the cut location create poor machining conditions. These hurdles can further increase tool wear and can compromise finished surface quality.

As you may have noticed, choosing the most suitable titanium for your product depends on the properties and applications you want. If you are trying to develop products for medical applications, you may want to choose the grade 23 titanium. Alternatively, if you are looking for a piece with excellent performance at elevated temperatures, you should consider working with grade 6 titanium.

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One of the biggest obstacles to machining titanium is keeping everything cool. Titanium’s low thermal conductivity makes the metal workpiece rapidly accumulate heat at the tooling location. This increases the wear on machining tools and has the secondary effect of hardening the titanium, which then further exacerbates the tool wear. If not addressed, this can detrimentally affect the quality of cut surfaces.

Unfortunately, some of the properties that make it so unique and valuable to product designers also make machining titanium incredibly difficult.

With different alloying elements come different mechanical properties for each titanium grade, meaning you can pick just the right titanium alloy for your application. Check out the following table to discover more about each alloy and to find out about it’s relative machinability!

Machining titanium requires careful temperature management. One of the most obvious ways to keep the workpiece and tooling cool is to apply consistent, high-pressure coolant directed to the cut area. Blasting the chips out of the cut area also keeps them from adhering to your machining tools.

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Titanium is already prone to causing tool chatter, so anything you can do reduce vibration will make machining titanium easier. Ensure parts are well-supported and secured to prevent deflection in the workpiece. Use high-quality CNC machines with very stiff tooling arrangements. You can even consider using shorter cutting tools to reduce tool deflection.

The challenges of titanium machining are enough to make many machine shops wary of working with this advanced material. But its outstanding properties mean more and more product designers are looking to have quality parts made from titanium. Luckily, expert machinists and tooling suppliers have come up with a few key ways to make machining titanium at least a little bit easier.

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