Multi-Objective Process Optimization of Micro-Milling Titanium Alloy Ti6Al4V for Microgrooves

High-quality microgrooves obtained in micro-milling titanium alloy Ti6Al4V are still challenging work due to the dependence of burr formation and surface roughness on cutting parameters. In this paper, the systematic analysis of the micro-milling process was conducted to obtain high-quality titanium alloy Ti6Al4V microgrooves, which is based on single-factor experiments, orthogonal experiments, intuitive analysis, range analysis, regression analysis, and multi-objective optimization. The range of factors and factors of orthogonal experiments were determined by single-factor experiments. Orthogonal experiments were conducted with a three-factor three-level design, which regards the total top-burr width and the bottom surface roughness of microgrooves as the response variables, and factors are spindle speed, feed per tooth, and the axial depth of cut. The optimal cutting parameters, which minimize the surface roughness and burr formation, and the main influence factor were determined by intuitive analysis, range analysis, regression analysis, and NSGA-II multi-objective optimization. Simultaneously, high-quality complex microgrooves were achieved with the optimal cutting parameters. The method of systematic experimental design and data analysis in this paper can provide the theoretical guideline and technical support for the processing development of complex parts.