Turning Data Optimization of Titanium Alloy Produced by Casting and DMLS

Area of Science:

• Materials Science
• Manufacturing Engineering
• Mechanical Engineering

Background:

• Additive manufacturing (e.g., direct metal laser sintering - DMLS) creates unique microstructures in titanium alloys like Ti6Al4V.
• These microstructures differ from conventionally cast materials, impacting mechanical properties and fabrication processes.
• Longitudinal turning is a critical finishing operation for components made from these materials.

Purpose of the Study:

• To investigate the challenges in machining Ti6Al4V produced by casting and DMLS.
• To develop a method for optimizing finishing cutting parameters.
• To minimize specific cutting force while maintaining high machined surface quality.

Main Methods:

• Experimental analysis of longitudinal turning of Ti6Al4V (cast and DMLS).
• Evaluation of cutting data influence on cutting forces, surface roughness, and chip morphology.
• Testing material hardening and specific cutting force variation with cutting layer cross-sectional shape.
• Application of a proposed optimization algorithm.

Main Results:

• Cutting parameters significantly influence cutting forces, surface roughness, and chip formation.
• Material hardening during machining was observed and analyzed.
• Specific cutting force was found to vary with the cutting layer's cross-sectional shape.
• A reduction in specific cutting force from 2300 N/mm² to 1950 N/mm² was achieved by altering the cutting layer cross-section, without compromising surface quality.

Conclusions:

• The cross-sectional shape of the cutting layer is a critical factor in optimizing the turning of Ti6Al4V.
• Machining parameters can be adjusted to reduce cutting forces significantly.
• It is possible to achieve improved machining efficiency for additively manufactured Ti6Al4V without sacrificing surface integrity.