A Ti-6Al-4V Milling Force Prediction Model Based on the Taylor Factor Model and Microstructure Evolution of the...

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Processes

Background:

• Milling titanium alloys like Ti-6Al-4V presents challenges due to their material properties.
• Accurate prediction of milling forces is crucial for process optimization and tool life.
• Understanding microstructure evolution during milling impacts surface integrity and performance.

Purpose of the Study:

• To establish a reliable milling force prediction model for Ti-6Al-4V that incorporates the Taylor factor.
• To investigate the influence of milling parameters (depth of cut, feed rate) on milling forces.
• To analyze the effects of milling parameters on the microstructure evolution of the Ti-6Al-4V surface.

Main Methods:

• Development of a milling force prediction model considering the Taylor factor.
• Experimental milling of Ti-6Al-4V with dynamometer-based force measurement.
• Microstructure analysis using Electron Backscatter Diffraction (EBSD) before and after milling.

Main Results:

• The developed model accurately predicts tangential and normal milling forces for Ti-6Al-4V with average errors below 10%.
• Milling depth was identified as the most influential parameter on milling forces among those studied.
• Milling parameters significantly alter surface microstructure, including grain structure, size, boundaries, phase distribution, and micro-texture, with plastic deformation governed by slip.

Conclusions:

• The Taylor factor-based milling force prediction model is reliable for Ti-6Al-4V.
• Milling depth and feed rate directly impact milling forces, with depth having a greater effect.
• Milling processes induce significant microstructural changes on the Ti-6Al-4V surface, primarily through slip mechanisms.