Machinability Analysis of Finish-Turning Operations for Ti6Al4V Tubes Fabricated by Selective Laser Melting

Abstract

With the advent of additive manufacturing as an advanced technology for the fabrication of titanium components, there is a pressing need to investigate the machinability of parts produced using these techniques compared to components made with conventional wrought methodologies. The motivation for this study was to investigate the influences of machining parameters, especially cutting depth, on the machinability of selective laser melted (SLMed) Ti6Al4V tubes, by analyzing the cutting responses, including cutting forces, machined surface roughness and tool wear at varying cutting parameters. Generally, it can be inferred that specific cutting tools used to machine wrought titanium components can also be used for SLMed parts when carrying out finish-machining operations. Cutting forces in the machining of SLMed workpieces could be up to 70% higher than those in machining the wrought counterparts. In contrast, the tool-wear analysis correspondingly showed larger tool-workpiece engagement area on the tool rake face for tools used for machining wrought parts. Adhesion on the cutting edge in the form of built-up edge and attrition of the tool surface were found to be the two most dominant tool-wear mechanisms, and the oxidation condition of the tool surface in machining SLMed parts was more severe (about 8% and 21%). Vibration analysis was also carried out, but no significant difference between the SLMed and wrought workpieces was observed, and the quality of the machined surface was similar.

Fabrication of Electron Beam Melted Titanium Aluminide: The Effects of Machining Parameters and Heat Treatment on Surface Roughness and Hardness

“…While there have been numerous studies on machining techniques for conventionally manufactured metallic parts [40], there is relatively limited research on machining methods specifically tailored for additively manufactured metals and alloys [41][42][43]. The existing studies in the literature mainly concentrate on Inconel 718 alloys [43], Ti6Al4V alloys [44], various steels [25,41], and aluminum alloys [26] for additively manufactured materials and machining of additively manufactured materials. Due to factors such as availability, cost, and commercial confidentiality, the research focus on TiAl alloys has been limited, resulting in a relatively small number of studies conducted on this particular material.…”

CNC Turning of an Additively Manufactured Complex Profile Ti6Al4V Component Considering the Effect of Layer Orientations

“…In both SLM and wrought Ti6Al4V parts, micro-cutting did not significantly alter subsurface microstructures. Li et al [25] investigated the turning of SLM and wrought Ti6Al4V tubes and studied the tool wear, machined surface roughness, and cutting forces at various feed rates, cutting depths, and cutting speeds. The rake face of the tools had a larger contact area with the wrought workpiece.…”

Preparation, Microstructure, and Interface Quality of Cr3C2-NiCr Cladding Layer on the Surface of Q235 Steel

“…R. A. Rahman Rashid et al [31] studied LPHT treatment, which can be effectively employed for localized control of the microstructure in the laser clad-repaired parts by tuning the laser reheat parameters. G. X. Li et al [32] studied the influence of machining parameters on the machinability of selective laser melted (SLMed) Ti6Al4V tubes, including cutting forces, machined surface roughness, and tool wear at varying cutting parameters.…”