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<p>Maintaining high surface integrity in Ti-6Al-4&#xa0;V milling remains challenging because severe force–thermal coupling accelerates tool wear and exacerbates surface damage. Although coating, edge passivation, and micro-texturing have each been shown to improve machinability, their coupled effects on titanium alloy surface integrity, particularly at specific texture scales, remain insufficiently understood. In this study, a micro-textured coating blunt edge (MTCBE) tool was evaluated in Ti-6Al-4&#xa0;V milling to clarify its effects on key surface integrity indicators. Relative to a coating blunt edge (CBE) tool, the MTCBE tool reduced surface roughness from 0.456 to 0.404 <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\:\mu\:m\)</EquationSource> </InlineEquation> (11.34%), decreased white layer thickness from 10.2 to 7.01 <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\:\mu\:m\)</EquationSource> </InlineEquation> (30.0%), and lowered exit-burr height from 112.3 to 87.48 <InlineEquation ID="IEq3"> <EquationSource Format="TEX">\(\:\mu\:m\)</EquationSource> </InlineEquation> (22.13%), while increasing surface microhardness from 345.35 to 358.1 HV (5.0%). Edge radius was identified as the dominant factor governing surface roughness and microhardness, whereas the minimum white layer thickness was achieved at an intermediate edge radius, indicating that surface integrity depends on the coordinated control of tool geometry and force–thermal conditions. Overall, the MTCBE tool effectively suppresses plastic deformation and enhances the surface integrity of milled Ti-6Al-4&#xa0;V, thereby providing quantitative guidance for the design of high performance tools for titanium alloy machining.</p>

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Study on the impact of tool fabrication combining micro-texture, coating, and edge rounding techniques on surface integrity in titanium alloy milling

  • 期刊论文

  • 发表日期：

    2026年3月29日

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  • Yiming Liu,
  • Shucai Yang,
  • Pei Han

摘要

Maintaining high surface integrity in Ti-6Al-4 V milling remains challenging because severe force–thermal coupling accelerates tool wear and exacerbates surface damage. Although coating, edge passivation, and micro-texturing have each been shown to improve machinability, their coupled effects on titanium alloy surface integrity, particularly at specific texture scales, remain insufficiently understood. In this study, a micro-textured coating blunt edge (MTCBE) tool was evaluated in Ti-6Al-4 V milling to clarify its effects on key surface integrity indicators. Relative to a coating blunt edge (CBE) tool, the MTCBE tool reduced surface roughness from 0.456 to 0.404 \(\:\mu\:m\) (11.34%), decreased white layer thickness from 10.2 to 7.01 \(\:\mu\:m\) (30.0%), and lowered exit-burr height from 112.3 to 87.48 \(\:\mu\:m\) (22.13%), while increasing surface microhardness from 345.35 to 358.1 HV (5.0%). Edge radius was identified as the dominant factor governing surface roughness and microhardness, whereas the minimum white layer thickness was achieved at an intermediate edge radius, indicating that surface integrity depends on the coordinated control of tool geometry and force–thermal conditions. Overall, the MTCBE tool effectively suppresses plastic deformation and enhances the surface integrity of milled Ti-6Al-4 V, thereby providing quantitative guidance for the design of high performance tools for titanium alloy machining.