Experiments and finite element simulations on micro-milling of Ti-6Al-4V alloy with uncoated and cBN coated micro-tools

This paper presents experimental investigations and finite element simulations on micro-milling of Ti-6Al-4V alloy with fine grain uncoated and cBN coated micro-end mills. Micro-milling of Ti-6Al-4V using uncoated and cBN coated tungsten carbide micro-end mills are conducted; surface roughness, burr formation and tool wear are measured. Effects of machining parameters on surface roughness, burr formation, and tool wear for uncoated and cBN coated micro-tools are investigated. Finite element modelling is utilized to predict forces, temperatures, and wear rate for uncoated and cBN coated micro-tools. Predicted temperature and tool wear contours for uncoated and cBN coated micro-tool edges reveal advantages of cBN coatings. Optimization studies on the experimental results are also conducted to identify the optimum process parameters which minimize both surface roughness and burr formation concurrently. (C) 2011 CIRP.