The effects of different tool wear patterns on the machining process of titanium alloys were investigated via the finite element simulation method. Initially

four kinds of tool wear patterns including the crater wear dominated pattern

the flank wear dominated pattern

the combined crater and flank wear dominated pattern and the edge blunting dominated pattern were established according to the actual tool wear geometrical dimensions. Then

the AdvantEdge software was used to develop the numerical models of machining Ti6Al4V using worn cemented carbide tools and to conduct the finite element analysis. The results indicate that the edge tip temperature decreases as the crater wear increases

the tensile stresses on the workpiece surface increase but the compressive stresses reduce as the flank wear increases. In the case of the combined crater and flank wear

the chip radius was decreased significantly as the tool wear extent intensifies. The edge blunting was found to have the most significant impact on the cutting forces

and the plowing effects become more pronounced when the edge radius is close to the feed rate.