End milling Ti-6Al-4V using a solid mill cutter was conducted based on the design-of-experiments approach. A multi-view method has been provided to characterize three-dimensional (3D) chip morphology and properties. Each view of the 3D chip morphology shows different characteristics. The microstructural analysis shows that a beta phase deforms severely and transforms to an alpha phase in the second shear zone. The phase transformation further leads to microhardness variations characterized by higher hardness at the surface and lower hardness in the immediate subsurface. In addition, the shear band as well as the corner section of the chip shows increased hardness. Published in the Transactions of NAMRI/SME
, Vol. 36, 2008, pp. 9-16.