Measurement and analysis of tool wear and surface characteristics in micro turning of SLM Ti6Al4V and wrought Ti6Al4V. (January 2023)

• Record Type: Journal Article
• Authors: Airao, Jay; Kishore, Hreetabh; Nirala, Chandrakant K.
• Is Part Of: Measurement. Volume 206(2023)
• Publication Date: 2023-01
• Subjects: Tool wear -- Surface characteristics -- Micro turning -- Selective laser melting -- Additive manufacturing -- Ti6Al4V; Weights and measures -- Periodicals; Measurement -- Periodicals; Measurement; Weights and measures; Periodicals; 530.8
• DOI: 10.1016/j.measurement.2022.112281
• Languages: English
• ISSNs: 0263-2241

Abstract

Highlights: Micro-turning experimentation of wrought SLM Ti6Al4V and wrought Ti6Al4V. Exploring size effect in micro turning for a given range of process parameters. Measurement and comparative analysis of tool wear and surface characteristics. Equiaxed gains of wrought Ti6Al4V found to be producing lesser tool wear than SLM Ti6Al4V. Instability of β-phase and higher hardness are responsible for relatively poor machinability of SLM Ti6Al4V. Abstract: Parts produced using additive manufacturing (AM) have a significant transition in the features such as surface quality, residual stresses, microhardness, etc. To make the AM component suitable for an application, post-processing of the parts is required to remove the non-desirable features. In this regard, the micro turning of selective laser melted (SLM) Ti6Al4V are conducted to examine the surface characteristics, tool wear and chip morphology. The results obtained for SLM Ti6Al4V are compared with the results of wrought Ti6Al4V. Attributed to the higher strength and hardness, the SLM Ti6Al4V shows a higher tool wear and surface roughness than the wrought Ti6Al4V. The main tool wear mechanisms involved are built-up edge formation, adhesion, abrasion, and edge chipping for both the materials. The surface roughness is found increased with increasing cutting speed and feed. The wrought Ti6Al4V shows less feed marks and chip adhesion compared to SLM Ti6Al4V. Moreover, the materials side flow is observed in SLM Ti6Al4V only. The chips produced are long and continuous for wrought Ti6Al4V, whereas they are discontinuous for SLM Ti6Al4V. Morphology of the chips shows that they are of scaly structure for SLM Ti6Al4V for all the parameters, whereas they are of lamella structure for wrought Ti6Al4V, particularly at low feed and cutting speed.