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Influence of the material manufacturing process on micromilling Ti6Al4V alloy

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Abstract

In order to obtain miniaturised products, additive manufacturing (AM) combined with micromachining presents a great potential on reducing manufacturing costs and material waste. The machinability of metals in general is well known for conventional machining processes. However, for micromachining processes, there are still gaps regarding the material’s behaviour. Likewise, the machinability of materials obtained by additive manufacturing still needs to be investigated. In this context, the present work aims to compare the micromilling process of an additive manufactured Ti6Al4V alloy produced by laser powder bed fusion (LPBF) and a commercial wrought Ti6Al4V alloy. The samples were examined through scanning electron microscope (SEM), energy-dispersive x-ray spectroscopy (EDS), and Vickers hardness measurements. No statistical differences were obtained when comparing the machining forces, burr formation, and surface roughness when micromilling the AM and wrought alloys. It was observed that the minimum chip thickness was not achieved in the experiments with higher tool diameter and lower feed per tooth, which led to a different workload on each edge of the tool. Better surface roughness was obtained in the combination of higher cutting speed and lower tool diameter. The experiments with lower material removal rate led to higher burr formation. From these analyses, it is possible to better understand the machinability of the Ti6Al4V alloy produced by AM.

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Acknowledgements

The authors thank the National Council for Scientific and Technological Development (CNPq) for the financial support and Omnitek BR for providing the samples.

Funding

This work was supported by the National Council for Scientific and Technological Development (CNPq), award number: 133231/2019-4

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Authors and Affiliations

  1. Polytechnic School of Engineering (Poli-USP), University of São Paulo, Av. Prof. Luciano Gualberto, Butantã, 05508-010, SP, Brazil

    Maria Clara Coimbra Gonçalves, Rodrigo Lima Stoeterau & Gilmar Ferreira Batalha

  2. Mechanical Engineering Department, University of Sheffield, Mappin Street, Sheffield, S1 3JD, UK

    Maria Clara Coimbra Gonçalves

  3. Federal University of Uberlândia, Av. João Naves de Ávila, Santa Mônica, 38408-100, MG, Brazil

    Milla Caroline Gomes & Márcio Bacci da Silva

  4. Mechanical Engineering Department, Universidade Estadual de Campinas, Campinas, Brazil

    Milla Caroline Gomes

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  1. Maria Clara Coimbra Gonçalves
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Maria Clara Coimbra Goncalves and Milla Caroline Gomes. The first draft of the manuscript was written by Maria Clara Coimbra Goncalves, edited by Milla Caroline Gomes and all authors commented on previous versions of the manuscript.

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Correspondence to Maria Clara Coimbra Gonçalves.

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The original online version of this article was revised: The original version of this article unfortunately contained a mistake on the Figures’ labels order from Fig. 7.

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Coimbra Gonçalves, M.C., Caroline Gomes, M., Lima Stoeterau, R. et al. Influence of the material manufacturing process on micromilling Ti6Al4V alloy. Int J Adv Manuf Technol 129, 23–35 (2023). https://doi.org/10.1007/s00170-023-12215-1

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