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<p>Machining of additively manufactured (AMed) Ti6Al4V alloy remains challenging for achieving the desired final surface quality, particularly during slot milling operations. This research investigates the influence of machining parameters on geometric integrity (slot accuracy, burr formation, surface roughness) and tool wear during slot milling of selective laser melting (SLM) AMed Ti6Al4V alloy. The milling process was performed under dry conditions using a full factorial design of experiments. Burr width, slot width, and tool wear were analysed via scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Additionally, optical 3D measurements and stylus-based roughness measurements of the machined slot were conducted. The results show an improvement of 59%, 71%, and 83% in burr formation, surface roughness, and tool life, respectively. Therefore, it demonstrates the effects of cutting speed, feed rate and depth of cut on slot accuracy, with a precise slot achieved under 60&#xa0;m/min, 0.1&#xa0;mm/rev, and 0.5&#xa0;mm. Additionally, the results highlighted a useful reference, which established optimal cutting parameters, with a major focus on SLM-AMed Ti6Al4V, slot geometric integrity, particularly slot width deviation, and burr formation, and their correlation with surface roughness and tool wear under a dry cutting environment. In summary, the safe machining window for slot milling of AMed Ti6Al4V alloy involves cutting speeds (60–120&#xa0;m/min), low feed rates (0.1&#xa0;mm/rev), and shallow to moderate cuts (0.25–0.5&#xa0;mm). This causes a loose fit tolerance and poor precision, which negatively impacts cutting performance and the geometric features of AM- machined parts.</p>

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Machining performance of additively manufactured Ti–6Al–4V: effects on surface and geometric integrity and tool wear during milling

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年8月5日

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  • Abdulkadir Mohammed Sambo,
  • Muhammad Younas,
  • James Njuguna,
  • Islam Shyha

摘要

Machining of additively manufactured (AMed) Ti6Al4V alloy remains challenging for achieving the desired final surface quality, particularly during slot milling operations. This research investigates the influence of machining parameters on geometric integrity (slot accuracy, burr formation, surface roughness) and tool wear during slot milling of selective laser melting (SLM) AMed Ti6Al4V alloy. The milling process was performed under dry conditions using a full factorial design of experiments. Burr width, slot width, and tool wear were analysed via scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Additionally, optical 3D measurements and stylus-based roughness measurements of the machined slot were conducted. The results show an improvement of 59%, 71%, and 83% in burr formation, surface roughness, and tool life, respectively. Therefore, it demonstrates the effects of cutting speed, feed rate and depth of cut on slot accuracy, with a precise slot achieved under 60 m/min, 0.1 mm/rev, and 0.5 mm. Additionally, the results highlighted a useful reference, which established optimal cutting parameters, with a major focus on SLM-AMed Ti6Al4V, slot geometric integrity, particularly slot width deviation, and burr formation, and their correlation with surface roughness and tool wear under a dry cutting environment. In summary, the safe machining window for slot milling of AMed Ti6Al4V alloy involves cutting speeds (60–120 m/min), low feed rates (0.1 mm/rev), and shallow to moderate cuts (0.25–0.5 mm). This causes a loose fit tolerance and poor precision, which negatively impacts cutting performance and the geometric features of AM- machined parts.