Skip to main content
SpringerLink
Log in

Effect of temperature buildup on milling forces in additive/subtractive hybrid manufacturing of Ti-6Al-4V

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

An additive/subtractive hybrid manufacturing (ASHM) combines the advantages of both additive and subtractive processes for fabricating complex parts of a better quality. While in an additive manufacturing process, temperature buildup is fast because of heat accumulation from a laser or electron beam, which exerts a great influence on the successive subtractive process. This study firstly measures the temperature variation of a Ti-6Al-4V workpiece in the direct material deposition (DMD) process, and then designs a heating device for a milling experiment at elevated temperatures. The effect of temperature buildup on milling forces is investigated through the experiment and a 2D thermal-mechanical coupling model. For work hardening effect and rapid tool wear, the milling forces are hardly decreased when the preheating temperature is lower than 300 °C. At a preheating temperature of 300 °C or higher, a significant reduction in milling forces is recorded, which may be attributed to the thermal softening effect on the workpiece material. The decreasing trend is more obvious at a larger feed-per-tooth. The thermal softening effect is reflected in the deformation layer in the subsurface of the machined workpiece. The study provides a guide to the determination of ASHM process parameters for Ti-6Al-4V.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Nazir A, Abate KM, Kumar A, Jeng J-Y (2019) A state-of-the-art review on types, design, optimization, and additive manufacturing of cellular structures. Int J Adv Manuf Technol 104:1–22

    Article  Google Scholar 

  2. Su X, Yang Y, Xiao D, Luo Z (2013) An investigation into direct fabrication of fine-structured components by selective laser melting. Int J Adv Manuf Technol 64(9–12):1231–1238

    Article  Google Scholar 

  3. Kumar S, Sharma V, Choudhary AKS, Chattopadhyaya S, Hloch S (2013) Determination of layer thickness in direct metal deposition using dimensional analysis. Int J Adv Manuf Technol 67(9–12):2681–2687

    Article  Google Scholar 

  4. Soboyejo WO, Srivatsan TS (2006) Advanced structural materials: properties, design optimization, and applications. Scitech Book News, vol 2. CRC press, Boca Raton

    Book  Google Scholar 

  5. Malekipour E, El-Mounayri H (2018) Common defects and contributing parameters in powder bed fusion AM process and their classification for online monitoring and control: a review. Int J Adv Manuf Technol 95(1–4):527–550

    Article  Google Scholar 

  6. Zhang B, Li Y, Bai Q (2017) Defect formation mechanisms in selective laser melting: a review. Chin J Mech Eng 30(3):515–527

    Article  Google Scholar 

  7. Flynn JM, Shokrani A, Newman ST, Dhokia V (2016) Hybrid additive and subtractive machine tools–research and industrial developments. Int J Mach Tool Manu 101:79–101

    Article  Google Scholar 

  8. Du W, Bai Q, Wang Y, Zhang B (2018) Eddy current detection of subsurface defects for additive/subtractive hybrid manufacturing. Int J Adv Manuf Technol 95(9–12):3185–3195

    Article  Google Scholar 

  9. Liu J, Wang X, Wang Y (2017) A complete study on satellite thruster structure (STS) manufactured by a hybrid manufacturing (HM) process with integration of additive and subtractive manufacture. Int J Adv Manuf Technol 92(9–12):4367–4377

    Article  Google Scholar 

  10. Xiong X, Zhang H, Wang G (2009) Metal direct prototyping by using hybrid plasma deposition and milling. J Mater Process Technol 209(1):124–130

    Article  Google Scholar 

  11. Ye ZP, Zhang ZJ, Jin X, Xiao MZ, Su JZ (2017) Study of hybrid additive manufacturing based on pulse laser wire depositing and milling. Int J Adv Manuf Technol 88(5–8):1–12

    Google Scholar 

  12. Du W, Bai Q, Zhang B (2016) A novel method for additive/subtractive hybrid manufacturing of metallic parts ☆. Procedia Manuf 5:1018–1030

    Article  Google Scholar 

  13. Swarnakar AK, Biest OVD, Baufeld B (2011) Thermal expansion and lattice parameters of shaped metal deposited Ti–6Al–4V. J Alloys Compd 509(6):2723–2728

    Article  Google Scholar 

  14. Ginta TL, Amin AKMN (2013) Thermally-assisted end milling of titanium alloy Ti-6Al-4V using induction heating. Int J Mach Mach Mater 14(2):194–212

    Google Scholar 

  15. Dandekar CR, Shin YC, Barnes J (2010) Machinability improvement of titanium alloy (Ti–6Al–4V) via LAM and hybrid machining. Int J Mach Tool Manu 50(2):174–182

    Article  Google Scholar 

  16. Sun S, Brandt M, Dargusch MS (2010) Thermally enhanced machining of hard-to-machine materials—a review. Int J Mach Tool Manu 50(8):663–680

    Article  Google Scholar 

  17. Sun S, Brandt M, Barnes JE, Dargusch MS (2011) Experimental investigation of cutting forces and tool wear during laser-assisted milling of Ti-6Al-4V alloy. P I Mech Eng B-J Eng 225(9):1512–1527

  18. Rashidab RAR, Sun S, Wang G, Dargusch MS (2012) An investigation of cutting forces and cutting temperatures during laser-assisted machining of the Ti–6Cr–5Mo–5V–4Al beta titanium alloy. Int J Mach Tool Manu 63:58–69

    Article  Google Scholar 

  19. Hedberg GK, Shin YC, Xu L (2015) Laser-assisted milling of Ti-6Al-4V with the consideration of surface integrity. Int J Adv Manuf Technol 79(9–12):1645–1658

    Article  Google Scholar 

  20. Yang D, Liu Z, Ren X, Zhuang P (2016) Hybrid modeling with finite element and statistical methods for residual stress prediction in peripheral milling of titanium alloy Ti-6Al-4V. Int J Mech Sci 108:29–38

    Article  Google Scholar 

  21. Dinda GP, Song L, Mazumder J (2008) Fabrication of Ti-6Al-4V scaffolds by direct metal deposition. Metall Mater Trans A 39(12):2914–2922

  22. Polishetty A, Shunmugavel M, Goldberg M, Littlefair G (2016) Singh RK (2016) cutting force and surface finish analysis of machining additive manufactured titanium alloy Ti-6Al-4V. Procedia Manufacturing 7:284–289

    Article  Google Scholar 

  23. Milton S, Morandeau A, Chalon F, Leroy R (2016) Influence of finish machining on the surface integrity of Ti6Al4V produced by selective laser melting. Procedia CIRP 45:127–130

    Article  Google Scholar 

  24. Bordin A, Bruschi S, Ghiotti A, Bucciotti F, Facchini L (2014) Comparison between wrought and EBM Ti6Al4V machinability characteristics. Key Eng Mater 611-612:1186–1193

    Article  Google Scholar 

  25. Chen G, Ren C, Yang X, Jin X, Guo T (2011) Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model. Int J Adv Manuf Technol 56(9–12):1027–1038

    Article  Google Scholar 

  26. Fahad M (2012) A heat partition investigation of multilayer coated carbide tools for high speed machining throughexperimental studies and finite element modelling. The University of Manchester (United Kingdom), Manchester

    Google Scholar 

  27. Thepsonthi T, Özel T (2013) Experimental and finite element simulation based investigations on micro-milling Ti-6Al-4V titanium alloy: effects of cBN coating on tool wear. J Mater Process Technol 213(4):532–542

    Article  Google Scholar 

  28. Ding H, Shen N, Shin YC (2012) Thermal and mechanical modeling analysis of laser-assisted micro-milling of difficult-to-machine alloys. J Mater Process Technol 212(3):601–613

    Article  Google Scholar 

  29. Waldorf DJ (1996) Shearing, ploughing, and wear in orthogonal machining. University of Illinois, Urbana-Champaign

    Google Scholar 

  30. Hou Y, Zhang D, Wu B, Luo M (2014) Milling force modeling of worn tool and tool flank wear recognition in end milling. IEEE-ASME T Mech 20(3):1024–1035

  31. Ducobu F, Arrazola PJ, Rivière-Lorphèvre E, Filippi E (2015) Finite element prediction of the tool wear influence in Ti6Al4V machining. Procedia CIRP 31:124–129

    Article  Google Scholar 

  32. Zamani H, Hermani J-P, Sonderegger B, Sommitsch C (2013) 3D simulation and process optimization of laser assisted milling of Ti6Al4 V. Procedia CIRP 8:75–80

    Article  Google Scholar 

  33. Deng WJ, Xia W, Tang Y (2009) Finite element simulation for burr formation near the exit of orthogonal cutting. Int J Adv Manuf Technol 43(9–10):1035

    Article  Google Scholar 

  34. Wu YC (2014) FEM simulation of milling tool wear for titaninum alloys TC4. Shangdong University, Jinan

    Google Scholar 

  35. Seo S, Min O, Yang H (2005) Constitutive equation for Ti–6Al–4V at high temperatures measured using the SHPB technique. Int J Impact Eng 31(6):735–754

    Article  Google Scholar 

  36. Parida AK, Maity K (2019) Hot machining of Ti–6Al–4V: FE analysis and experimental validation. Sādhanā 44(6):142

    Article  Google Scholar 

  37. Bermingham M, Sim W, Kent D, Gardiner S, Dargusch M (2015) Tool life and wear mechanisms in laser assisted milling Ti–6Al–4V. Wear 322:151–163

    Article  Google Scholar 

  38. Zhou JM, Bushlya V, Peng RL, Johansson S, Avdovic P, Stahl JE (2011) Effects of tool wear on subsurface deformation of nickel-based superalloy. Procedia Engineering 19(1):407–413

    Article  Google Scholar 

  39. Liu CR, Barash MM (1976) The mechanical state of the sublayer of a surface generated by chip-removal process—part 2: cutting with a tool with flank wear. J Eng Ind 98(4):1202

    Article  Google Scholar 

  40. Altintas Y, Ber AA (2001) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Appl Mech Rev 54(5):B84

    Article  Google Scholar 

Download references

Funding

The financial supports from the International cooperative research project of Shenzhen Science and Technology Innovation Commission (GJHZ20180411143506667) are gratefully acknowledged.

Author information

Authors and Affiliations

  1. Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen, 518055, China

    Shuai Li & Bi Zhang

  2. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Shuai Li

  3. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China

    Qian Bai

Authors
  1. Shuai Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Bi Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Qian Bai
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Bi Zhang.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, S., Zhang, B. & Bai, Q. Effect of temperature buildup on milling forces in additive/subtractive hybrid manufacturing of Ti-6Al-4V. Int J Adv Manuf Technol 107, 4191–4200 (2020). https://doi.org/10.1007/s00170-020-05309-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05309-7

Keywords

Search

Navigation