Sustainable high-speed milling enhancement of GnP-reinforced titanium nanocomposites under dry environment

Abstract

No studies have been done on using graphene nanostructure reinforcement material to improve titanium alloy's dry high-speed machining performance, which is crucial for green manufacturing. This study seeks to understand the impact of graphene on improving the high-speed machining of Ti6Al4V (Ti64) nanocomposites. High-density Ti64-based nanocomposite samples with varying amounts of GnPs (0 wt%, 0.6 wt%, 1.2 wt%, and 2.4 wt%) were fabricated using ball milling and HFIHS sustainable technologies. Subsequently, a detailed investigation was conducted to examine the impact of the GnP contents on high-speed milling performance, namely, cutting force components, surface quality, and machined surface and subsurface microhardness. The variable milling parameters include the cutting speed and feed rate. The results showed that the inclusion of GnPs significantly affected the dry high-speed milling of the nanocomposites. The nanocomposites containing 1.2 wt% and 2.4 wt% of GnP-Ti64 exhibited lower cutting forces than the base-Ti64 without GnP (0 wt% Gnp). At a 100 m/min cutting speed, the cutting and feed forces decreased by 35% and 44%, respectively, compared to the base-Ti64 specimens. This is attributed to lower machining friction due to the presence of graphene and TiC (formed due to the reaction of Ti and GnP particles during sintering) at grain boundaries, facilitating material removal and reducing cutting force. Although the nanocomposites had a higher microhardness, they all showed improved surface quality in comparison to the base-Ti64 specimens. For example, at a feed rate of 270 mm/min the nanocomposites contain 0.6 wt%, 1.2 wt%, and 2.4 wt.% GnPs showed roughness reductions of 6%, 27%, and 38%, respectively, compared to the base-Ti64. Regarding surface and sub-surface hardness after machining, the 2.4 wt.% GnP samples showed superior performance in terms of minimal post-milling hardness variations compared to the base hardness of the material. All GnP-Ti64 milled specimens showed considerably improved surface morphology compared to the base-Ti64 machined specimens. Overall, the nanocomposites containing 1.2 wt% and 2.4 wt% GnPs are strong contenders for reducing cutting forces, enhancing surface roughness, and lowering the fluctuations in microhardness, leading to green manufacturing.