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Study on machinability of additively manufactured and conventional titanium alloys in micro-milling process
Affiliation:1. Department of Industrial Engineering, University of Padova, Via Venezia 1, 35131, Padova, Italy;2. Department of Mechanical, Energy and Management Engineering, University of Calabria, Via P. Bucci Edificio Cubo 46 C, 87036, Arcavacata di Rende, CS, Italy;3. Department of Mechanical Engineering, Technical University of Denmark, Nils Koppels Allé Building 404, DK-2800, Kgs. Lyngby, Denmark;1. Department of Mechanical, Energy and Management Engineering, University of Calabria, Rende, CS, 87036, Italy;2. Department of Environmental and Chemical Engineering, University of Calabria, Rende, CS, 87036, Italy;3. Department of Informatics Modeling, Electronics and System Engineering, University of Calabria, Rende, CS, 87036, Italy
Abstract:Capability of Additive Manufacturing (AM) technology in the production of complex parts with high flexibility has led to the growing interest in their application as an alternative for conventional manufacturing processes. Despite the outstanding benefits of the AM process, due to their poor surface quality, the precision parts produced by this method generally need to be machined, ground, or polished. This paper addresses the machinability of AM Ti6Al4V titanium alloy parts in the micro-milling process with a specific focus on cutting forces, specific cutting energy, burr formation, and surface quality. Additive parts were produced by Electron Beam Melting (EBM) technique and were compared with the extruded Ti6Al4V parts in the micro-milling process. No significant difference could be observed in the cutting forces of both materials at chip thicknesses between 7.4 and 37.3 μm, despite the higher hardness of the EBM Ti6Al4V compared to the extruded Ti6Al4V. However, micro-milling of the EBM parts produced finer surfaces. Cutting forces and specific cutting energies of EBM parts were less than those of extruded parts at minimal chip thicknesses (lower than 7.4 μm). Continuous wavy-type burrs were formed in micro-milling of the EBM Ti6Al4V and were larger than those of extruded Ti6Al4V.
Keywords:Micro milling  Additive manufacturing  EBM  Specific cutting energy  Surface quality  Burr formation
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