<p>Additively manufactured Ti-6Al-4V parts often undergo secondary machining to meet the requirements of dimensional tolerances, surface finish, and fatigue life. Machining additively manufactured Ti-6Al-4V parts exhibits distinctive challenges compared to machining wrought or cast counterparts, owing to the difference in as-built microstructure in AM. This review documents state-of-the-art findings in the conventional machining of AM-processed Ti-6Al-4V alloys, with a particular focus on the tool wear aspect of machinability. Peer reviewed publications and conference presentations from the period 2020 to 2025 are primarily considered in this report. Following a fundamental discussion on the tool wear mechanisms, this report presents a thorough review of the influence of microstructural attributes on tool wear, and key strategies to reduce tool wear in machining these alloys. It has been elucidated that, compared to wrought/cast counterparts, tool wear effects are significantly higher and are governed by microstructural anisotropy in machining AM-processed Ti-6Al-4V alloy. Further, this report discerns that improving tribology at the tool-chip and tool-workpiece interface is the most popular strategy for reducing tool wear in machining this alloy. However, there are several shortcomings in this strategy that need to be addressed, and other underexplored tool wear reduction strategies also need further investigation, as realised herein. The future outlook on the subject research domain is presented at the end of this report while summarising the review findings.</p>

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Tool wear in machining additively manufactured Ti-6Al-4V alloys: a brief state-of-the-art overview

  • Harshal Kulkarni,
  • Vitoon Uthaisangsuk

摘要

Additively manufactured Ti-6Al-4V parts often undergo secondary machining to meet the requirements of dimensional tolerances, surface finish, and fatigue life. Machining additively manufactured Ti-6Al-4V parts exhibits distinctive challenges compared to machining wrought or cast counterparts, owing to the difference in as-built microstructure in AM. This review documents state-of-the-art findings in the conventional machining of AM-processed Ti-6Al-4V alloys, with a particular focus on the tool wear aspect of machinability. Peer reviewed publications and conference presentations from the period 2020 to 2025 are primarily considered in this report. Following a fundamental discussion on the tool wear mechanisms, this report presents a thorough review of the influence of microstructural attributes on tool wear, and key strategies to reduce tool wear in machining these alloys. It has been elucidated that, compared to wrought/cast counterparts, tool wear effects are significantly higher and are governed by microstructural anisotropy in machining AM-processed Ti-6Al-4V alloy. Further, this report discerns that improving tribology at the tool-chip and tool-workpiece interface is the most popular strategy for reducing tool wear in machining this alloy. However, there are several shortcomings in this strategy that need to be addressed, and other underexplored tool wear reduction strategies also need further investigation, as realised herein. The future outlook on the subject research domain is presented at the end of this report while summarising the review findings.