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<p>The subsurface plastic deformation of milled TC4 titanium alloy critically affects workpiece fatigue performance. To resolve contradictory reports regarding its occurrence, this study investigates the influence of measurement direction through experiments and simulations. The results indicate that plastic deformation is distinct in the vertical feed direction but negligible in the feed direction. Finite element simulations reveal the underlying mechanism: the maximum von Mises stress in the 0-20&#xa0;μm subsurface layer reaches 1299.4&#xa0;MPa, significantly exceeding the material’s yield strength. This high-stress state provides the essential mechanical driving force for plastic deformation. Furthermore, the stress attenuates sharply with depth, which explains the limited depth of the deformation layer. These findings clarify the deformation mechanism and provide a basis for controlling surface quality.</p>

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Investigation on the Different Characteristics of Subsurface Plastic Deformation Measured Between Parallel and Vertical Feed Direction during Milling TC4 Titanium Alloy

  • 期刊论文

  • 发表日期：

    2026年3月10日

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  • Yibo Yang,
  • Cunke Niu,
  • Zinan Ye,
  • Ning Hou,
  • Minghai Wang,
  • Yuxin Zhang

摘要

The subsurface plastic deformation of milled TC4 titanium alloy critically affects workpiece fatigue performance. To resolve contradictory reports regarding its occurrence, this study investigates the influence of measurement direction through experiments and simulations. The results indicate that plastic deformation is distinct in the vertical feed direction but negligible in the feed direction. Finite element simulations reveal the underlying mechanism: the maximum von Mises stress in the 0-20 μm subsurface layer reaches 1299.4 MPa, significantly exceeding the material’s yield strength. This high-stress state provides the essential mechanical driving force for plastic deformation. Furthermore, the stress attenuates sharply with depth, which explains the limited depth of the deformation layer. These findings clarify the deformation mechanism and provide a basis for controlling surface quality.