Turning of Additively Manufactured Ti6Al4V: Effect of the Highly Oriented Microstructure on the Surface Integrity

Lizzul, Lucia; Bertolini, Rachele; Ghiotti, Andrea

doi:10.3390/ma14112842

Cited by 8 publications

(2 citation statements)

References 30 publications

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“…Another study [31] investigated the influence of laser-powder bed fused (L-PBF) fabrication Stainless Steel 316 L part orientations during milling by tuning the layer thickness through the L-PBF process. Furthermore, Lizzul et al [32] studied L-PBF fabricated Ti6Al4V components using altered scanning strategies (chessboard and stripes) and improved surface integrity during turning operations while considering the layers' orientations (cylindrical (across the layers) and transverse operations (along layers)). The results showed that the unique microstructure induced by the L-PBF process affects the machinability of the material depending on the strategy of scanning and/or layers orientation.…”

Section: Introductionmentioning

confidence: 99%

CNC Turning of an Additively Manufactured Complex Profile Ti6Al4V Component Considering the Effect of Layer Orientations

et al. 2023

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Electron beam melting (EBM) is one example of a 3D printing technology that has shown great promise and advantages in the fabrication of medical devices such as dental and orthopedic implants. However, these products require high surface quality control to meet the specifications; thus, post-processing, such as with machining processes, is required to improve surface quality. This paper investigates the influence of two-part orientations of Ti6Al4V EBM parts on the CNC machining (turning) process. The two possible EBM part orientations used in this work are across EBM layers (AL) and parallel to the EBM layer (PL). The effect of the EBM Ti6Al4V part orientations is examined on surface roughness, power consumption, chip morphology, tool flank wear, and surface morphology during the dry turning, while using uncoated carbide tools at different feed rates and cutting speeds. The results showed that the AL orientation had better surface quality control and integrity after machining than PL orientation. Using the same turning parameters, the difference between the roughness (Ra) value for AL (0.36 μm) and PL (0.79 μm) orientations is about 54%. Similarly, the power consumption in AL orientation differs by 19% from the power consumption in PL orientation. The chip thickness ratio has a difference of 23% between AL and PL orientations, and the flank wear shows a 40% difference between AL and PL orientations. It is found that, when EBM components are manufactured along across-layer (AL) orientations, the impact of part orientation during turning is minimized and machined surface integrity is improved.

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Section: Introductionmentioning

confidence: 99%

CNC Turning of an Additively Manufactured Complex Profile Ti6Al4V Component Considering the Effect of Layer Orientations

et al. 2023

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“…Variation of microstructure occurs at different AM processes which thus influences surface integrity after subtractive manufacturing. Lizzul et al 14 investigated the influence of microstructure on surface integrity during turning of laser powder bed fused Ti-6Al-4V components which are fabricated by different scanning techniques. Machining was influenced by microstructural anisotropy and the effect of cryogenic cooling was more on anisotropy for assessment of surface integrity.…”

Section: Introductionmentioning

confidence: 99%

Study on machinability characteristics of novel additive manufactured titanium alloy (Ti-6Al-4V) fabricated by direct metal laser sintering

Sahoo

Routara

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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The pressing demand of Ti-6Al-4V (grade 5) in aerospace, medical, marine, and chemical processing industries has gained momentum in recent years due to its excellent properties such as high strength to weight ratio and corrosion resistance, bio-compatibility and a common material for additive manufacturing. Additive manufactured Ti-6Al-4V have higher mechanical properties as compared to wrought alloys due to difference in microstructure that negatively influences the machinability characteristics and also lacks ductility. The main limitation of fabricated additive manufactured (AMed) component is the poor surface quality, staircase effect and adhering of non-melted powder particles to the fabricated components. Again, fatigue life of components increases with decrease of surface roughness. Therefore the need of machining of AMed titanium alloys in recent years are gaining importance to eliminate these problems so that desired surface quality and tolerances can be achieved. Therefore the objective of the study is to develop additive manufactured Ti-6Al-4V through direct metal laser sintering process and investigate its machinability characteristics under flood cooling environment with respect to responses as tool wear, surface roughness, cutting temperature, and chip morphology. As most of the heat generated at the interfaces has been carried away through flood cooling, the rate of growth of tool wear, cutting temperature, surface roughness, and degree of serration decreases and thus makes the performance of AMed Ti alloys are comparable with wrought Ti alloys. The dominant tool wear mechanism during machining AMed Ti alloy have been found to be abrasion, chipping, adhesion, BUE, chemical interaction between titanium and cutting tool materials, coating delamination. Optimal parameters for multi-responses are 0.1 mm depth of cut, 0.1 mm/rev feed rate, and 70 m/min cutting speed and improved. Mathematical models are said to be significant and fitted well. Because of the improved machinability, AMed Ti alloys find itself suitable in industrial applications.

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Ball end milling machinability of additively and conventionally manufactured Ti6Al4V tilted surfaces

Lizzul

Sorgato

Bertolini

et al. 2021

Journal of Manufacturing Processes

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Turning of Additively Manufactured Ti6Al4V: Effect of the Highly Oriented Microstructure on the Surface Integrity

Cited by 8 publications

References 30 publications

CNC Turning of an Additively Manufactured Complex Profile Ti6Al4V Component Considering the Effect of Layer Orientations

CNC Turning of an Additively Manufactured Complex Profile Ti6Al4V Component Considering the Effect of Layer Orientations

Study on machinability characteristics of novel additive manufactured titanium alloy (Ti-6Al-4V) fabricated by direct metal laser sintering

Ball end milling machinability of additively and conventionally manufactured Ti6Al4V tilted surfaces

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