Skip to main content

Advertisement

SpringerLink
Log in

Micro milling of titanium alloy Ti-6Al-4V: 3-D finite element modeling for prediction of chip flow and burr formation

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Cutting process of titanium alloy Ti-6Al-4V is considered difficult due to chemical affinity between tool and work material, adhesion, built-up edge and burr formation, and tool wear resulting in loss of productivity. Three dimensional (3-D) chip flow together with local field variables such as temperature, elastic/plastic strain, strain-rate and velocity in the shear zones during micro milling process can be predicted using continuum-mechanics based 3-D Finite Element (FE) modelling and simulation of elastic/viscoplastic work material deformations. This paper provides much needed process insight for chip flow, built-up edge and burr formation by using modeling work with experimental validation. Scanning electron microscopic (SEM) observation of the 3-D chip morphology and burrs demonstrate ductile fractured surfaces together with localized instability and failure behaviors. FE simulations are utilized to investigate the effects of micro milling operation i.e. up and down milling and tool edge radius on 3-D chip flow, built-up edge, and 3-D burr formation. Simulated results are compared with measurements of chip morphology, shape, and dimensions together with tool edge condition of built-up edge and chip adhesion yielding to good agreements.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. Altintas Y, Jin X (2011) Mechanics of micro-milling with round edge tools. CIRP Ann Manuf Technol 60(1):77–80

    Article  Google Scholar 

  2. Aurich JC, Dornfeld D, Arrazola PJ, Franke V, Leitz L, Min S (2009) Burrs—analysis, control and removal. CIRP Ann Manuf Technol 58:519–542

    Article  Google Scholar 

  3. Biermann D, Kahnis P (2010) Analysis and simulation of size effects in micromilling. Prod Eng Res Dev 4(1):25–34

    Article  Google Scholar 

  4. Chen MJ, Ni HB, Wang ZJ, Jiang Y (2012) Research on the modeling of burr formation process in micro-ball end milling operation on Ti-6Al-4 V. Int J Adv Manuf Technol 62:901–912

    Article  Google Scholar 

  5. Denkena B, Biermann D (2014) Cutting edge geometries. CIRP Ann Manuf Technol 63:631–653

    Article  Google Scholar 

  6. Dornfeld D, Mina S, Takeuchi Y (2006) Recent advances in mechanical micromachining. CIRP Ann Manuf Technol 55:745–768

    Article  Google Scholar 

  7. Gelfi M, Attanasio A, Ceretti E, Garbellini A, Pola A (2015) Micromilling of lamellar Ti6Al4V: cutting force analysis. Mater Manuf Process 31(7):919–925

    Article  Google Scholar 

  8. Gillespie LK, Blotter PT (1976) The formation and properties of machining burrs. Trans ASME Ser B 98(1):66–74

    Article  Google Scholar 

  9. Jaffery SI, Mativenga PT (2009) Assessment of the machinability of Ti-6Al-4V alloy using the wear map approach. Int J Adv Manuf Technol 40:687–696

    Article  Google Scholar 

  10. Ko SL, Dornfeld DA (1996) Analysis of fracture in burr formation at the exit stage of metal cutting. J Mater Process Technol 58(2–3):189–200. doi:10.1016/0924-0136(95)02124-8

    Google Scholar 

  11. Kruy S, Aoyama H, Ohta K, Sano N (2014) Prediction of thickness and height of burr based on burr formation mechanisms in end milling. Bull JSME 8(4):14-00084

    Google Scholar 

  12. Özel T, Thepsonthi T, Ulutan D, Kaftanoğlu B (2011) Experiments and finite element simulations on micro-milling of Ti-6Al-4V alloy with uncoated and cBN coated micro-tools. CIRP Ann Manuf Technol 60(1):85–88

    Article  Google Scholar 

  13. Oliaei SNB, Karpat Y (2016) Investigating the influence of built-up edge on forces and surface roughness in micro scale orthogonal machining of titanium alloy Ti6Al4V. J Mater Process Technol 235:28–40

    Article  Google Scholar 

  14. Özel T, Bartolo P, Ceretti E, Ciurana J, Rodriguez CA, Lopes Da Silva JV (2016) Biomedical devices: design, prototyping and manufacturing. Wiley, Hoboken

    Book  Google Scholar 

  15. Pramanik A, Littlefair G (2015) Machining of titanium alloy (Ti-6Al-4V)—theory to application. Mach Sci Technol Int J 19:1–49

    Article  Google Scholar 

  16. Riviere-Lorphevre E, Letot C, Ducobu F, Dehombreux P, Filippi E (2017) Dynamic simulation of milling operations with small diameter milling cutters: effect of material heterogeneity on the cutting force model. Meccanica 52:35–44

    Article  Google Scholar 

  17. Schulze V, Autenrieth H, Deuchert M, Weule H (2010) Investigation of surface near residual stress states after micro-cutting by finite element simulation. CIRP Ann Manuf Technol 59:117–120

    Article  Google Scholar 

  18. Storchak M, Jiang L, Xu L, Li X (2016) Finite element modeling for cutting process of the titanium alloy Ti10V2Fe3Al. Prod Eng Res Dev 10(405):509–517

    Article  Google Scholar 

  19. Thepsonthi T, Özel T (2015) 3-D finite element process simulation of micro-end milling Ti-6Al-4V titanium alloy: experimental validations on chip flow and tool wear. J Mater Process Technol 221:128–145

    Article  Google Scholar 

  20. Thepsonthi T, Özel T (2016) Simulation of serrated chip formation in micro-milling of titanium alloy Ti-6Al-4V using 2D elasto-viscoplastic finite element modeling. Prod Eng Res Dev 10(6):575–586

    Article  Google Scholar 

  21. Uhlmann E, Oberschmidt D, Kuche Y, Löwenstein A (2014) Cutting edge preparation of micro milling tools. Proced CIRP 14:349–354

    Article  Google Scholar 

  22. Wang JJ, Uhlmann E, Oberschmidt D, Sung CF, Perfilov I (2016) Critical depth of cut and asymptotic spindle speed for chatter in micro milling with process damping. CIRP Ann Manuf Technol 65(1):113–116

    Article  Google Scholar 

Download references

Acknowledgements

The support provided by DEFORM software by SFTC, Ohio, USA is gratefully acknowledged.

Author information

Authors and Affiliations

  1. Manufacturing and Automation Research Laboratory, Rutgers, The State University of New Jersey Industrial and Systems Engineering, 96 Frelinghuysen Road, Piscataway, NJ, 08854, USA

    Tuğrul Özel & Alaa Olleak

  2. Department of Industrial Engineering, Burapha University, Chonburi, Thailand

    Thanongsak Thepsonthi

Authors
  1. Tuğrul Özel
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Alaa Olleak
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Thanongsak Thepsonthi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Tuğrul Özel.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Özel, T., Olleak, A. & Thepsonthi, T. Micro milling of titanium alloy Ti-6Al-4V: 3-D finite element modeling for prediction of chip flow and burr formation. Prod. Eng. Res. Devel. 11, 435–444 (2017). https://doi.org/10.1007/s11740-017-0761-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-017-0761-4

Keywords

Search

Navigation