Titanium alloys are well known for their excellent strength-to-weight ratio and corrosion resistance and is highly sought after in the aerospace industry. This study focused on experimental evaluation of laser-assisted milling (LAML) of a Ti-6AL-4V (Ti-64) workpiece which uses localized preheating of the workpiece by a laser and characterizes the improvements to the machinability of these metals. The benefits of LAML are quantified for laser parameters which are shown to maintain final surface integrity of the heat-treatable workpiece after the machining process. Laser parameters are determined based on temperature prediction modeling. Laser preheating is shown to reduce cutting force during the machining process. Machinability improvement is characterized through inspection of flank wear on the cutting tool using LAML and traditional machining methods and comparing total tool life. Systematic characterization of samples is performed using hardness measurements, scanning electron microscopy (SEM), and X-ray diffraction (XRD) to ensure that material properties remained unaltered as a result of laser preheating. An economic analysis is performed for LAML to characterize the improvement obtained despite the additional costs associated with the laser equipment.

This study presents the experimental evaluation of laser assisted milling (LAML) of Ti-6AL-4V ELI (Ti-64), which is used in the orthopedic industry, by using localized preheating of the workpiece via laser irradiation. Improvements to the machinability of this material with LAML are assessed while considering the surface integrity. Suitable laser heating conditions as well as machining conditions are determined based on temperature prediction modeling. Machinability improvements are shown in terms of tool wear, material removal rates and cutting force reduction. Systematic characterization of samples is shown to demonstrate that the machined sub-surfaces are not adversely affected during LAML by precisely controlling laser heating, via hardness measurements, scanning electron microscopy (SEM) for microstructure analysis, and X-ray diffraction (XRD) for residual stresses. An economic analysis shows that LAML provides the cost reduction over conventional machining.