LASER HYBRID MICRO MILLING OF Ti6Al4V (Ti-grade 5)

Abstract

Ti6A14V is deemed suitable for high thermal applications, and it is considered a ''Workhouse'' material in the aerospace industry. Salient features of Ti6Al4V include high strength to density ratio and outstanding material properties at high temperatures. This study examines the responses of Burr width, burr height, surface roughness and flank tool wear in Laser hybrid Micro-milling, as conventional machining is not suitable for this ''Hard to Machine'' alloys. Laser engraving parameters like scan speed, power and frequency are combined with milling parameters of cutting speed, feed, and depth of cut in this experiment. Burr width, burr height in up milling and down milling directions, surface roughness and flank tool wear are analysed using ANOVA. Burr width has feed as the most contributing factor on the upmilling and down milling sides with a contribution of 42.35 % and 54.21 % respectively. Burr height has the depth of cut as the highest factor for up milling and down milling sides with the contribution of 47.49 % and 45.16 % respectively. Main effect plots presented the combination of parameters for minimum and maximum burr width and height on both milling sides. Surface roughness has the depth of cut as the most contributing factor with a percentage of 41.27%. Tool wear at the left flank has feed per tooth as the most contributing factor with a percentage of 49.47%. Similarly, feed contributes the most to right flank tool wear with a percentage of 54.20%. Main effect plots present the combination of milling parameters for maximum and minimum surface roughness and flank tool wear.