Laser pre-structure-assisted micro-milling of Ti6Al4V titanium alloy

High flexibility of the micro-milling process compared to nontraditional methods has led to its growing application in manufacturing complex micro-parts with tight tolerances and high accuracies. However, difficulties such as tool deflection, size effect, and tool wear limit the application of micro-milling. In this regard, the role of laser-assisted machining (LAM) is highlighted to prevent mentioned issues through reduction of machining forces and providing the possibility for using higher feeds. Ti6Al4V as a hard-to-machine material is chosen as the workpiece material. Unlike traditional LAM, Ti6Al4V parts were structured using a picosecond laser before micro-milling. The influence of laser structuring at different structure densities on the reduction of machining forces was analyzed at two feeds of 10 and 50 mu m/tooth at a constant cutting speed of 35 m/min. A remarkable reduction in cutting forces was observed at both feeds. Additionally, the role of structure density in cutting force reduction is highlighted.