Investigation of roughness, topography, microhardness, white layer and surface chemical composition in high speed milling of Ti-6Al-4V using minimum quantity lubrication

Abstract

In this research, the effects of high speed milling on the main surface integrity characteristics, including surface roughness and topography, microhardness, white layer thickness, and surface chemical composition of Ti-6Al-4V were empirically studied. Totally, 18 experiments were carried out using a full factorial design of experiments method in the presence of minimum quantity lubricant. The results showed that by using high speed milling, it is possible to reach the surfaces with a higher quality and surface roughness of approximately 0.2 μm. Also, it was discovered that the microhardness variation with cutting speed has a dual nature. The maximum microhardness was obtained at the cutting speed of 375 m/min and the feed rate of 0.08 mm/tooth, which showed a 57% increase compared with the bulk material. In addition, by using the cutting speed of 450 m/min, the depth of heat-affected layer and work hardening effects declined up to 75% in comparison with the cutting speed of 300 m/min.

Keywords:

• High speed milling
• minimum quantity lubrication method
• surface integrity
• Ti-6Al-4V

Notes

1 Computer Aided Design

2 Computer Aided Manufacturing

3 Built-Up-Edge

4 High Speed Milling

5 Minimum Quantity Lubrication

6 Computational Fluid Dynamics

7 Polycrystalline Diamond

8 Polycrystalline Cubic Boron Nitride

9 Energy Dispersive Spectroscopy

10 Wire-Electro Discharge Machining

11 Scanning Electron Microscopy