Investigations on improving the machining performances in micro turning of ti 6al 4v

Abstract

Micro turning is a mechanical micromachining technique, widely used for the newlinemanufacturing of micro shafts, micro pins, biomedical and dental implants, etc., with newlinefeature sizes ranging from 1 500 and#956;m. Ti-6Al-4V alloy is used for many applications, newlinedue to its biocompatibility, high strength to weight ratio and superior mechanical newlineproperties. However, Ti-6Al-4V is considered as a difficult to machine alloy due to the newlinelow thermal conductivity, chemical affinity to the tool materials, spring back effect, etc. newlineIn the case of micromachining, as the minimum uncut chip thickness becomes newlinecomparable with the cutting edge radius, the size effect becomes influential, resulting in newlinea non-linear variation in the specific cutting energy. Thus, the micro turning of Ti-6Al- newline4V alloy is associated with rapid tool wear, resulting in poor surface finish. The majority newlineof the studies reported in the past, focused on understanding the process mechanics, the newlineinfluence of size effect phenomenon, optimizing the cutting parameters, etc., on soft newlinematerials such as brass, magnesium, aluminium, etc. Recent studies on the micro turning newlineof Ti-6Al-4V, involved analytical and finite element modelling of the machining process, newlinefor the prediction of machining forces and surface roughness. In the current study, tool newlinewear prediction for micro turning and strategies to improve the machining performances newlinein the micro turning of Ti-6Al-4V, such as application of minimum quantity lubrication newline(MQL) and cutting tool texturing for micro turning applications, under different cutting newlineconditions were investigated. newlineTool wear models are widely employed in the analytical prediction and finite element newlinesimulation of cutting tool wear in conventional machining. However, for the tool wear newlineprediction in micro turning, calibrated tool wear models are not available. newline