Abstract
This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti-6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.
Highlights
Titanium alloy Ti-6Al-4V is widely used in aerospace, automobile, marine, and biomedical industries because of its high strength to weight ratio, high corrosion resistance, and good biocompatibility [1]
Two types of titanium alloys were used in this study; these were wrought grade Ti-6Al-4V and additive manufactured selective laser melted (SLM) Ti-6Al-4V
Machining trials found selective laser melted titanium alloy SLM Ti-6Al-4V machined with higher tool wear, cutting forces, and machine surface roughness compared to wrought Ti-6Al-4V
Summary
Titanium alloy Ti-6Al-4V is widely used in aerospace, automobile, marine, and biomedical industries because of its high strength to weight ratio, high corrosion resistance, and good biocompatibility [1]. Several additive manufacturing techniques for processing of metals were proposed Some of these techniques use wire as initial material (e.g., shaped metal deposition) and others use metallic powders (e.g., selective laser sintering (SLS), selective laser melting (SLM), and electron beam melting (EBM)) [4, 5]. Each of these technologies has its own advantages and disadvantages. Murr et al [11] reported high strength and hardness of SLM Ti-6Al-4V are mainly due to the martensite phase regimes present in its microstructure
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