Determination of minimum uncut chip thickness under various machining conditions during micro-milling of Ti-6Al-4V

To optimize the machining process, finding the minimum uncut chip thickness is of paramount importance in micro-scale machining. However, strong dependency of the minimum uncut chip thickness to the tool geometry, workpiece material, tool-work friction, and process condition makes its evaluation complicated. The paper focuses on determination of the minimum uncut chip thickness experimentally during micro-end milling of titanium alloy Ti-6Al-4V with respect to influences of cutting parameters and lubricating systems. Experiments were carried out on a CNC machining center Kern Evo with two flute end mills of 0.8 and 2 mm diameters being used in the tests for micro- and macro-milling, respectively. It was found that the micro-milling caused more size effect than macro-milling due to higher surface micro-hardness and specific cutting forces. The specific cutting force depended strongly on feed rate (f (z)) and lubricating system, followed by depth of cut (a (p)) and cutting speed (v (c)), mainly in the micro-scale. All output parameters were inversely proportional to the specific cutting force. Finally, depending on different process parameters during micro-milling of Ti-6Al-4V, the minimum uncut chip thickness was found to vary between 0.15 and 0.49 of the tool edge radius.