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

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes

Background:

• Micro-milling titanium alloy Ti6Al4V presents challenges in achieving high-quality microgrooves.
• Burr formation and surface roughness are highly dependent on cutting parameters.

Purpose of the Study:

• To systematically analyze the micro-milling process of Ti6Al4V.
• To determine optimal cutting parameters for minimizing burr formation and surface roughness.
• To achieve high-quality microgrooves in titanium alloy Ti6Al4V.

Main Methods:

• Single-factor experiments to determine factor ranges.
• Orthogonal experiments (three-factor, three-level) with spindle speed, feed per tooth, and axial depth of cut.
• Intuitive analysis, range analysis, regression analysis, and NSGA-II multi-objective optimization.

Main Results:

• Optimal cutting parameters were identified to minimize burr width and surface roughness.
• The main influencing factors on microgroove quality were determined.
• High-quality complex microgrooves were successfully fabricated using the optimized parameters.

Conclusions:

• Systematic experimental design and data analysis provide a guideline for processing complex titanium alloy parts.
• The study offers theoretical guidance and technical support for advanced micro-milling applications.
• Optimized parameters are crucial for producing defect-free microgrooves in Ti6Al4V.