Titanium Speeds & Feeds Calculator 2026
Calculate optimal cutting parameters for aerospace-grade titanium alloys including Ti-6Al-4V, Ti-5553, Ti-6242, and commercially pure titanium. Get recommendations for turning, milling, and drilling operations with tool life and power estimates.
Calculate Titanium Cutting Parameters
Titanium Machining: Complete Guide 2026
Titanium and titanium alloys present unique machining challenges that make them among the most difficult materials to machine productively. This comprehensive guide covers everything you need to know about machining titanium, from understanding material properties to optimizing cutting parameters and selecting appropriate tooling.
Why Is Titanium Difficult to Machine?
Titanium presents several unique challenges compared to steel and aluminum:
Low Thermal Conductivity
Titanium's thermal conductivity (7 W/m·K) is only 4% of aluminum's. Heat generated during cutting cannot dissipate through the chip or workpiece, concentrating at the cutting edge and accelerating tool wear.
Chemical Reactivity
At elevated temperatures (above 500°C), titanium chemically reacts with most tool materials, causing rapid crater wear. This limits cutting speeds compared to steel machining.
Low Modulus of Elasticity
Titanium's modulus (114 GPa) is half that of steel. This causes workpiece deflection and springback, particularly in thin-walled parts, leading to chatter and dimensional issues.
Work Hardening Tendency
If the tool rubs instead of cuts (due to insufficient chip load), the titanium surface work hardens, becoming even more difficult to machine in subsequent passes.
Best Practices for Titanium Machining
1. Use High-Pressure Coolant
High-pressure coolant (70-100+ bar) is the single most effective strategy for improving titanium machining performance. Benefits include:
- 50-100% improvement in tool life compared to flood coolant
- Better chip breaking and evacuation, preventing bird's nesting
- More effective heat removal from the cutting zone
- Ability to increase cutting speeds by 20-30%
- Reduced built-up edge formation
2. Maintain Consistent Chip Load
Never allow the tool to rub against the titanium surface. Maintain minimum chip load:
- Milling: minimum 0.05 mm/tooth (0.002 inch/tooth)
- Turning: minimum 0.10 mm/rev (0.004 inch/rev)
- Use trochoidal milling for constant engagement
- Avoid dwelling in cuts or retracing without feed
3. Choose Appropriate Tool Materials
Tool selection is critical for titanium machining success:
- Best: Carbide with TiAlN or AlTiN coating
- Good: SiAlON ceramics for high-speed continuous cuts
- Acceptable: Uncoated carbide for drilling/tapping
- Avoid: PCD (diamond) - chemical affinity causes rapid wear
4. Use Sharp Tools with Positive Geometry
Tool geometry significantly impacts cutting forces and heat generation:
- Positive rake angle: 10-15° for lower cutting forces
- Relief angle: 6-10° to prevent rubbing
- Sharp cutting edges essential - replace tools at 0.3mm flank wear
- Consider variable helix end mills to reduce chatter
5. Ensure Rigid Setup
Machine and workpiece rigidity directly impact achievable parameters:
- Use hydraulic or shrink-fit toolholders (not collets)
- Minimize tool overhang - L/D ratio should be <4
- Ensure adequate workpiece clamping
- For thin walls, use light cuts and consider fixture design
Titanium Alloy Classification
Titanium alloys are classified by their crystal structure at room temperature:
Alpha Alloys
CP Titanium (Grades 1-4), Ti-5Al-2.5Sn
Best corrosion resistance and weldability. Easiest to machine. Cannot be heat treated.
Alpha-Beta Alloys
Ti-6Al-4V (most common), Ti-6Al-2Sn-4Zr-2Mo
Balanced properties. Heat treatable. Ti-6Al-4V accounts for 50% of all titanium used.
Beta Alloys
Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-10V-2Fe-3Al
Highest strength. Deep hardenability. Most difficult to machine - reduce parameters 25-30%.
Understanding Cutting Parameters
Cutting Speed (m/min or SFM)
The most critical parameter for tool life. Titanium speeds are 5-10× lower than aluminum. For Ti-6Al-4V with coated carbide: 30-60 m/min turning, 25-50 m/min milling. Increasing speed by just 10% can reduce tool life by 30-50% due to the exponential relationship (Taylor's equation).
Feed Rate
Unlike steel, increasing feed rate in titanium (within limits) can actually improve tool life by moving heat away from the cutting edge faster. Use 0.05-0.12 mm/tooth for milling, 0.15-0.30 mm/rev for turning. Never underfeeding - rubbing causes work hardening.
Depth of Cut
For roughing: up to 1.5× tool diameter axial depth with 40-50% radial engagement. For finishing: 0.1-0.3× diameter axial with 10-15% stepover. Deep cuts spread heat along more of the cutting edge, which can improve tool life compared to shallow passes.
⚠️ Safety Considerations for Titanium Machining
- Fire hazard: Fine titanium chips can ignite, especially with oil-based coolants or dry machining
- Never use water to extinguish titanium fires - use Class D (metal) fire extinguisher or dry sand
- Ensure adequate coolant flow before starting cuts
- Keep work area clean of accumulated chips
- Monitor tool wear closely - sudden tool failure can cause workpiece damage or fire
- Use proper PPE - titanium chips are sharp and can cause cuts
Titanium Machining Quick Reference 2026
| Alloy | Grade | UTS (MPa) | Hardness (HB) | Machinability | Work Hardening |
|---|---|---|---|---|---|
| Ti-6Al-4V (Grade 5) | Grade 5 | 895-1100 | 334 | 22% | high |
| Ti-6Al-4V ELI (Grade 23) | Grade 23 | 860-965 | 311 | 24% | moderate |
| Ti-6Al-2Sn-4Zr-2Mo | Ti-6242 | 1000-1170 | 340 | 18% | very-high |
| Ti-5Al-5Mo-5V-3Cr (Ti-5553) | Ti-5553 | 1050-1250 | 380 | 15% | very-high |
| Ti-3Al-2.5V (Grade 9) | Grade 9 | 620-760 | 249 | 35% | moderate |
| Ti-6Al-7Nb | IMI 367 | 900-1050 | 320 | 23% | high |
| Commercially Pure Ti Grade 1 | Grade 1 | 240-345 | 120 | 55% | low |
| Commercially Pure Ti Grade 2 | Grade 2 | 345-485 | 160 | 50% | low |
| Commercially Pure Ti Grade 4 | Grade 4 | 550-680 | 253 | 40% | moderate |
Machinability: Higher percentage = easier to machine. Ti-6Al-4V (22%) is the baseline for aerospace alloys.
Work Hardening: Higher tendency requires consistent chip load to prevent surface hardening.
Frequently Asked Questions
For Ti-6Al-4V with TiAlN-coated carbide tools, the optimal cutting speed is 45-60 m/min (150-200 SFM) for turning and 35-50 m/min (115-165 SFM) for milling. With high-pressure coolant (70+ bar), you can increase speeds by 20-30%. Always start conservative at 70-80% of maximum and adjust based on actual performance.
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