Laser pre-structure-assisted micro-milling of Ti6Al4V titanium alloy

• Published in: International journal of advanced manufacturing technology Vol. 120; no. 3-4; pp. 1765 - 1776
• Main Authors: Hojati, Faramarz, Azarhoushang, Bahman, Daneshi, Amir, Biermann, Dirk
• Format: Journal Article
• Language: English
• Published: London Springer London 01.05.2022; Springer Nature B.V
• Subjects: CAE) and Design; Computer-Aided Engineering (CAD; Cutting force; Cutting parameters; Cutting speed; Engineering; Industrial and Production Engineering; Lasers; Mechanical Engineering; Media Management; Milling (machining); Original Article; Reduction; Size effects; Titanium alloys; Titanium base alloys; Tolerances; Tool wear; Workpieces; Micro-milling; LAM; Cutting forces; Structure density
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-022-08774-4

High flexibility of the micro-milling process compared to nontraditional methods has led to its growing application in manufacturing complex micro-parts with tight tolerances and high accuracies. However, difficulties such as tool deflection, size effect, and tool wear limit the application of micro-milling. In this regard, the role of laser-assisted machining (LAM) is highlighted to prevent mentioned issues through reduction of machining forces and providing the possibility for using higher feeds. Ti6Al4V as a hard-to-machine material is chosen as the workpiece material. Unlike traditional LAM, Ti6Al4V parts were structured using a picosecond laser before micro-milling. The influence of laser structuring at different structure densities on the reduction of machining forces was analyzed at two feeds of 10 and 50 µm/tooth at a constant cutting speed of 35 m/min. A remarkable reduction in cutting forces was observed at both feeds. Additionally, the role of structure density in cutting force reduction is highlighted.