Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64
Selective laser melting (SLM) is a three-dimensional (3D) printing process that can manufacture functional parts with complex geometries as an alternative to using traditional processes, such as machining wrought metal. If precision and a high surface finish are required, particularly for creating m...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-05-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/14/6/1160 |
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| author | Uçan Karakılınç Berkay Ergene Bekir Yalçın Kubilay Aslantaş Ali Erçetin |
| author_facet | Uçan Karakılınç Berkay Ergene Bekir Yalçın Kubilay Aslantaş Ali Erçetin |
| author_sort | Uçan Karakılınç |
| collection | DOAJ |
| description | Selective laser melting (SLM) is a three-dimensional (3D) printing process that can manufacture functional parts with complex geometries as an alternative to using traditional processes, such as machining wrought metal. If precision and a high surface finish are required, particularly for creating miniature channels or geometries smaller than 1 mm, the fabricated parts can be further machined. Therefore, micro milling plays a significant role in the production of such miniscule geometries. This experimental study compares the micro machinability of Ti-6Al-4V (Ti64) parts produced via SLM compared with wrought Ti64. The aim is to investigate the effect of micro milling parameters on the resulting cutting forces (F<sub>x</sub>, F<sub>y</sub>, and F<sub>z</sub>), surface roughness (R<sub>a</sub> and R<sub>z</sub>), and burr width. In the study, a wide range of feed rates was considered to determine the minimum chip thickness. Additionally, the effects of the depth of cut and spindle speed were observed by taking into account four different parameters. The manufacturing method for the Ti64 alloy does not affect the minimum chip thickness (MCT) and the MCT for both the SLM and wrought is 1 μm/tooth. SLM parts exhibit acicular α martensitic grains, which result in higher hardness and tensile strength. This phenomenon prolongs the transition zone of micro-milling for the formation of minimum chip thickness. Additionally, the average cutting force values for SLM and wrought Ti64 fluctuated between 0.072 N and 1.96 N, depending on the micro milling parameters used. Finally, it is worth noting that micro-milled SLM workpieces exhibit lower areal surface roughness than wrought ones. |
| first_indexed | 2024-03-11T02:09:40Z |
| format | Article |
| id | doaj.art-c52ff2f3486a40c4b75b1a9bd079eb0e |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-11T02:09:40Z |
| publishDate | 2023-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-c52ff2f3486a40c4b75b1a9bd079eb0e2023-11-18T11:39:15ZengMDPI AGMicromachines2072-666X2023-05-01146116010.3390/mi14061160Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64Uçan Karakılınç0Berkay Ergene1Bekir Yalçın2Kubilay Aslantaş3Ali Erçetin4Department of Computer Programming, Isparta University of Applied Sciences, 32200 Isparta, TurkeyDepartment of Mechanical Engineering, Pamukkale University, 20160 Denizli, TurkeyDepartment of Mechanical Engineering, Afyon Kocatepe University, 03200 Afyonkarahisar, TurkeyDepartment of Mechanical Engineering, Afyon Kocatepe University, 03200 Afyonkarahisar, TurkeyDepartment of Naval Architecture and Marine Engineering, Faculty of Maritime, Bandırma Onyedi Eylul University, 10200 Bandırma, TurkeySelective laser melting (SLM) is a three-dimensional (3D) printing process that can manufacture functional parts with complex geometries as an alternative to using traditional processes, such as machining wrought metal. If precision and a high surface finish are required, particularly for creating miniature channels or geometries smaller than 1 mm, the fabricated parts can be further machined. Therefore, micro milling plays a significant role in the production of such miniscule geometries. This experimental study compares the micro machinability of Ti-6Al-4V (Ti64) parts produced via SLM compared with wrought Ti64. The aim is to investigate the effect of micro milling parameters on the resulting cutting forces (F<sub>x</sub>, F<sub>y</sub>, and F<sub>z</sub>), surface roughness (R<sub>a</sub> and R<sub>z</sub>), and burr width. In the study, a wide range of feed rates was considered to determine the minimum chip thickness. Additionally, the effects of the depth of cut and spindle speed were observed by taking into account four different parameters. The manufacturing method for the Ti64 alloy does not affect the minimum chip thickness (MCT) and the MCT for both the SLM and wrought is 1 μm/tooth. SLM parts exhibit acicular α martensitic grains, which result in higher hardness and tensile strength. This phenomenon prolongs the transition zone of micro-milling for the formation of minimum chip thickness. Additionally, the average cutting force values for SLM and wrought Ti64 fluctuated between 0.072 N and 1.96 N, depending on the micro milling parameters used. Finally, it is worth noting that micro-milled SLM workpieces exhibit lower areal surface roughness than wrought ones.https://www.mdpi.com/2072-666X/14/6/1160selective laser meltingcastingTi64micro-millingsurface quality |
| spellingShingle | Uçan Karakılınç Berkay Ergene Bekir Yalçın Kubilay Aslantaş Ali Erçetin Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64 Micromachines selective laser melting casting Ti64 micro-milling surface quality |
| title | Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64 |
| title_full | Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64 |
| title_fullStr | Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64 |
| title_full_unstemmed | Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64 |
| title_short | Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64 |
| title_sort | comparative analysis of minimum chip thickness surface quality and burr formation in micro milling of wrought and selective laser melted ti64 |
| topic | selective laser melting casting Ti64 micro-milling surface quality |
| url | https://www.mdpi.com/2072-666X/14/6/1160 |
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