Enhancing Micro-Milling Performance of Ti6Al4V
An Experimental Analysis of Ultrasonic Vibration Effects on Forces, Surface Topography, and Burr Formation
Abstract
The current study focuses on axial ultrasonic vibration-assisted micro-milling as an advanced technique to improve the machining performance of Ti6Al4V, a material whose difficult-to-cut properties present a significant barrier to manufacturing the high-quality micro-components essential for aerospace and biomedical applications. A full factorial design was employed to evaluate the influence of feed-per-tooth (fz), axial depth-of-cut (ap), and ultrasonic vibration on cutting forces, surface roughness, burr formation, and tool wear. Experimental results demonstrate that ultrasonic assistance significantly reduces cutting forces by 20.09% and tool wear by promoting periodic tool–workpiece separation and improving chip evacuation. However, it increases surface roughness due to the formation of uniform micro-dimples, which may enhance tribological properties. Burr dimensions were primarily governed by feed-per-tooth, with higher feeds minimizing burr size. The study provides actionable insights into optimizing machining parameters for cutting Ti6Al4V, highlighting the trade-offs between force reduction, surface texture, and burr control. These findings contribute to advancing ultrasonic-assisted micro-milling for industrial applications, namely aerospace and biomedical applications requiring high precision and extended tool life.
Details
- Organisationseinheit(en)
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Institut für Maschinenkonstruktion und Tribologie
- Externe Organisation(en)
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Egypt-Japan University of Science and Technology (E-JUST)
Alexandria University
- Typ
- Artikel
- Journal
- Journal of Manufacturing and Materials Processing
- Band
- 9
- Publikationsdatum
- 30.10.2025
- Publikationsstatus
- Veröffentlicht
- Peer-reviewed
- Ja
- ASJC Scopus Sachgebiete
- Werkstoffmechanik, Maschinenbau, Wirtschaftsingenieurwesen und Fertigungstechnik
- Elektronische Version(en)
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https://doi.org/10.3390/jmmp9110356 (Zugang:
Offen
)
