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<p>During the conventional machining of Ti-6Al-4V alloy, large amounts of lubricants are required as cooling agents or cutting fluids to mitigate heating and tool wear. However, cutting fluids adversely impacts the operator’s safety and environment. Dry machining was endorsed as an ideal sustainable alternative, but due to exceedingly high cutting temperatures, which rapidly reduce tool life and surface integrity, thereby rendering the technique infeasible for Ti-6Al-4V. In this study, 3D vibration assisted machining (VAM) was employed to address the difficulties with the dry machining of Ti-6Al-4V alloy; polycrystalline diamond (PCD) tools for enhanced cost-effectiveness and sustainability. The effects of 3D VAM on surface morphology, cutting force, surface roughness, chip morphology, and tool wear at various feed rates and depths of cut were analyzed. It was observed that 3D vibrations improve the surface finish at higher feed rates but increase the surface roughness at lower feed rates, due to overlapping tool marks. Additionally, while the overall cutting forces were reduced, noticeable negative impacts on tool wear and chip morphology were observed. These experimental results emphasize the need to continuously adjust the machining parameters to optimize 3D VAM for sustainable operation.</p>

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Sustainable dry machining of Ti-6 Al-4 V alloy via 3D resonant vibration assisted machining

  • 期刊论文

  • 发表日期：

    2025年6月4日

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  • Saood Ali,
  • Rendi Kurniawan,
  • Moran Xu,
  • Tae Jo Ko

摘要

During the conventional machining of Ti-6Al-4V alloy, large amounts of lubricants are required as cooling agents or cutting fluids to mitigate heating and tool wear. However, cutting fluids adversely impacts the operator’s safety and environment. Dry machining was endorsed as an ideal sustainable alternative, but due to exceedingly high cutting temperatures, which rapidly reduce tool life and surface integrity, thereby rendering the technique infeasible for Ti-6Al-4V. In this study, 3D vibration assisted machining (VAM) was employed to address the difficulties with the dry machining of Ti-6Al-4V alloy; polycrystalline diamond (PCD) tools for enhanced cost-effectiveness and sustainability. The effects of 3D VAM on surface morphology, cutting force, surface roughness, chip morphology, and tool wear at various feed rates and depths of cut were analyzed. It was observed that 3D vibrations improve the surface finish at higher feed rates but increase the surface roughness at lower feed rates, due to overlapping tool marks. Additionally, while the overall cutting forces were reduced, noticeable negative impacts on tool wear and chip morphology were observed. These experimental results emphasize the need to continuously adjust the machining parameters to optimize 3D VAM for sustainable operation.