Abstract
The additive manufactured titanium alloy has been extensively applied in medical and aerospace fields; the post-treatment machining is necessary to achieve the machining requirements. In this work, the titanium alloy prepared by SLM process was set as the experimental sample, and the tool wear experiment was carried out by using PCD micro end mill. Tool wear mechanisms and its influence on the machining process were investigated. The experimental results indicated that the irregular arc shape wear zones were produced on the rake face, clearance face, and bottom face, and resulting in a triangle wear zone generated at bottom face. The tool wear area on tool tip and rake face was applied to quantitatively evaluate tool wear process. The dominating wear mechanisms were adhesive wear, abrasive wear, microchipping behavior, and graphitization behavior. The cutting force shows an uptrend with tool wear process, especially the axial force. The maximum milling distance reaches 11,400 mm with tool wear area of 10,120 μm2 and the cutting resultant force of 20.4N. As the milling distance increases, the surface roughness fluctuation increases, and the material protrusion on the machined surface becomes obvious gradually.
Similar content being viewed by others
Data availability
The data sets supporting the results of this article are included within the article.
Code availability
Not applicable.
References
Pasang T, Budiman AS, Wang JC, Jiang CP, Boyer R, Williams J, Misiolek WZ (2023) Additive manufacturing of titanium alloys—enabling re-manufacturing of aerospace and biomedical components. Microelectron Eng 270(1):111935
Abeni A, Cappellini C, Ginestra PS, Attanasio A (2022) Analytical modeling of micro-milling operations on biocompatible Ti6Al4V titanium alloy. Procedia CIRP 110:8–13
Kaur M, Singh K (2019) Review on titanium and titanium based alloys as biomaterials for orthopaedic applications. Mater Sci Eng, C 102:844–862
Hourmand M, Sarhan AAD, Sayuti M, Hamdi M (2021) A comprehensive review on machining of titanium alloys. Arab J Sci Eng 46:7087–7123
Guo N, Leu MC (2013) Additive manufacturing: technology, applications and research needs. Front Mech Eng 8(3):215–243
Li G, Chandra S, Rashid RAR, Palanisamy S, Ding S (2022) Machinability of additively manufactured titanium alloys: a comprehensive review. J Manuf Process 75:72–79
Nagesha BK, Dhinakaran V, Varsha Shree M, Manoj Kumar KP, Jagadeesha T (2020) A review on weldability of additive manufactured titanium alloys. Mater Today: Proc 33(7):2964–2969
Harun WSW, Manam NS, Kamariah MSIN, Sharif S, Zulkifly AH, Ahmad I, Miura H (2018) A review of powdered additive manufacturing techniques for Ti-6al-4v biomedical applications. Powder Technol 331(15):74–97
Khanna N, Zadafiya K, Patel T, Kaynak Y, Abdul R, Rashid R, Vafadar A (2021) Review on machining of additively manufactured nickel and titanium alloys. J Market Res 15:3192–3221
Leila L, Maryam S (2021) Review of powder bed fusion additive manufacturing for metals. Metals 11(9):1391
Malakizadi A, Mallipeddi D, Dadbakhsh S, M’Saoubi R, Krajnik P (2022) Post-processing of additively manufactured metallic alloys—a review. Int J Mach Tools Manuf 179:103908
Lu J, Zhuo L (2023) Additive manufacturing of titanium alloys via selective laser melting: fabrication, microstructure, post-processing, performance and prospect. Int J Refract Metal Hard Mater 111:106110
Mamedov A (2021) Micro milling process modeling: a review. Manuf Rev 8:3
Hojati F, Daneshi A, Soltani B, Azarhoushang B (2020) Study on machinability of additively manufactured and conventional titanium alloys in micro-milling process. Precis Eng 62:1–9
Zhao G, Xin L, Li L, Zhang Y, He N, Hansen HN (2023) Cutting force model and damage formation mechanism in milling of 70wt% Si/Al composite. Chin J Aeronaut. https://doi.org/10.1016/j.cja.2022.07.018
Chen N, Li H, Wu J, Li Z, Li L, Liu G, He N (2021) Advances in micro milling: from tool fabrication to process outcomes. Int J Mach Tools Manuf 160:103670
Hao X, Chen M, Liu L, Han J, He N, Zhao G, Chen N (2020) Fabrication of large aspect ratio PCD micro-milling tool with pulsed lasers and grinding. J Manuf Process 58:489–499
Jagadesh T, Samuel GL (2017) Finite element simulations of micro turning of Ti-6Al-4V using PCD and coated carbide tools. J Inst Eng (India) Series C 98(1):5–15
Wu W, Li L, He N, Chen M, Zhao M (2012) An experimental study on micro-cutting machining of pure tungsten. Mater Sci Forum 1848(723–723):377–382
Wang S, Li L, He N, Bian R, Zhan Z, Liu J (2014) Research on tool wear of PCD micro end mill in machining of ZrO2 ceramics. Mater Sci Forum 3256(800–801):20–25
Wu X, Li L, He N, Zhao G, Jiang F, Shen J (2018) Study on the tool wear and its effect of PCD tool in micro milling of tungsten carbide. Int J Refract Metal Hard Mater 77:61–67
Pao WC, Ding SL, Mo J (2014) Thermal characteristics in milling Ti6Al4V with polycrystalline diamond tools. Int J Adv Manuf Technol 75:1077–1087
Nakamoto K, Katahira K, Ohmori H, Yamazaki K, Aoyama T (2012) A study on the quality of micro-machined surfaces on tungsten carbide generated by PCD micro end-milling. CIRP Ann Manuf Technol 61(1):567–570
Singh KK, Kartik V, Singh R (2015) Modeling dynamic stability in high-speed micromilling of Ti-6Al-4V via velocity and chip load dependent cutting coefficients. Int J Mach Tools Manuf 96:56–66
Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability—a review. J Mater Process Technol 68(3):262–274
Sartori S, Moro L, Ghiotti A, Bruschi S (2017) On the tool wear mechanisms in dry and cryogenic turning additive manufactured titanium alloys. Tribol Int 105:264–273
Vazquez E, Gomar J, Ciurana J, Rodríguez CA (2015) Analyzing effects of cooling and lubrication conditions in micromilling of Ti6Al4V. J Clean Prod 87(15):906–913
Funding
This work was supported by National Natural Science Foundation of China (51905182, 52275428) and Fundamental Research Funds for the Central Universities (ZQN-805).
Author information
Authors and Affiliations
Contributions
All persons who meet authorship criteria are listed as authors. Xian Wu is responsible for the overall research ideas in this paper; Zhongwei Chen and Wenchang Ke are responsible for micro milling experiments; Jianyun Shen and Feng Jiang are responsible for the tool wear inspection and analysis; Laifa Zhu and Congfu Fang offer the theoretical guidance in the research and writing process.
Corresponding author
Ethics declarations
Ethics approval
Not applicable.
Consent to participate
Consent to participate in this study was obtained from all the authors.
Consent for publication
Consent for publication was obtained from all the authors.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Chen, Z., Wu, X., Ke, W. et al. Tool wear mechanisms of PCD micro end mill in machining of additive manufactured titanium alloy. Int J Adv Manuf Technol 127, 3269–3280 (2023). https://doi.org/10.1007/s00170-023-11729-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-11729-y