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<p>Titanium alloys are widely classified as difficult-to-cut materials due to their low thermal conductivity and high chemical reactivity, which present significant machining challenges. This study provides a pioneering comparative analysis of the micro-drilling machinability under cryogenic cooling (−196&#xa0;°C) and thermally assisted drilling (TAD) using PID-controlled induction heating at 250&#xa0;°C and 500&#xa0;°C. Experimental results revealed that while cryogenic drilling increased thrust forces by approximately 38% compared to room temperature conditions, it exhibited superior performance in terms of chip morphology and surface integrity by reducing surface roughness (R<sub>a</sub>) values to as low as 0.34&#xa0;μm. Conversely, TAD at 250&#xa0;°C offered no machinability benefits, representing a thermal dead zone within the experimental constraints of the present study. However, at 500&#xa0;°C, thrust forces decreased by approximately 13% due to thermal softening, leading to significant improvements in burr morphology despite the increased risk of chip clogging and severe built-up layer formation due to adhesion. Additionally, regardless of the thermal environment, lower cutting speeds were found to be essential for maintaining process stability.</p>

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Unveiling the impact of workpiece temperature on Ti6Al4V micro-drilling through a comparative analysis of cryogenic and thermally assisted drilling

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年6月30日

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  • Sezer Morkavuk

摘要

Titanium alloys are widely classified as difficult-to-cut materials due to their low thermal conductivity and high chemical reactivity, which present significant machining challenges. This study provides a pioneering comparative analysis of the micro-drilling machinability under cryogenic cooling (−196 °C) and thermally assisted drilling (TAD) using PID-controlled induction heating at 250 °C and 500 °C. Experimental results revealed that while cryogenic drilling increased thrust forces by approximately 38% compared to room temperature conditions, it exhibited superior performance in terms of chip morphology and surface integrity by reducing surface roughness (Ra) values to as low as 0.34 μm. Conversely, TAD at 250 °C offered no machinability benefits, representing a thermal dead zone within the experimental constraints of the present study. However, at 500 °C, thrust forces decreased by approximately 13% due to thermal softening, leading to significant improvements in burr morphology despite the increased risk of chip clogging and severe built-up layer formation due to adhesion. Additionally, regardless of the thermal environment, lower cutting speeds were found to be essential for maintaining process stability.