Details
| Original language | English |
|---|---|
| Article number | 356 |
| Journal | Journal of Manufacturing and Materials Processing |
| Volume | 9 |
| Issue number | 11 |
| Publication status | Published - 30 Oct 2025 |
Abstract
The current study focuses on axial ultrasonic vibration-assisted micro-milling as an advanced technique to improve the machining performance of Ti6Al4V, a material whose difficult-to-cut properties present a significant barrier to manufacturing the high-quality micro-components essential for aerospace and biomedical applications. A full factorial design was employed to evaluate the influence of feed-per-tooth (fz), axial depth-of-cut (ap), and ultrasonic vibration on cutting forces, surface roughness, burr formation, and tool wear. Experimental results demonstrate that ultrasonic assistance significantly reduces cutting forces by 20.09% and tool wear by promoting periodic tool–workpiece separation and improving chip evacuation. However, it increases surface roughness due to the formation of uniform micro-dimples, which may enhance tribological properties. Burr dimensions were primarily governed by feed-per-tooth, with higher feeds minimizing burr size. The study provides actionable insights into optimizing machining parameters for cutting Ti6Al4V, highlighting the trade-offs between force reduction, surface texture, and burr control. These findings contribute to advancing ultrasonic-assisted micro-milling for industrial applications, namely aerospace and biomedical applications requiring high precision and extended tool life.
Keywords
- burr formation, chip thickness, cutting forces, size effect, surface roughness, Ti6Al4V, tool wear, ultrasonic-assisted micro-milling
ASJC Scopus subject areas
- Engineering(all)
- Mechanics of Materials
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Journal of Manufacturing and Materials Processing, Vol. 9, No. 11, 356, 30.10.2025.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Enhancing Micro-Milling Performance of Ti6Al4V
T2 - An Experimental Analysis of Ultrasonic Vibration Effects on Forces, Surface Topography, and Burr Formation
AU - Wadee, Asmaa
AU - Nassef, Mohamed G.A.
AU - Pape, Florian
AU - Maher, Ibrahem
N1 - Publisher Copyright: © 2025 by the authors.
PY - 2025/10/30
Y1 - 2025/10/30
N2 - The current study focuses on axial ultrasonic vibration-assisted micro-milling as an advanced technique to improve the machining performance of Ti6Al4V, a material whose difficult-to-cut properties present a significant barrier to manufacturing the high-quality micro-components essential for aerospace and biomedical applications. A full factorial design was employed to evaluate the influence of feed-per-tooth (fz), axial depth-of-cut (ap), and ultrasonic vibration on cutting forces, surface roughness, burr formation, and tool wear. Experimental results demonstrate that ultrasonic assistance significantly reduces cutting forces by 20.09% and tool wear by promoting periodic tool–workpiece separation and improving chip evacuation. However, it increases surface roughness due to the formation of uniform micro-dimples, which may enhance tribological properties. Burr dimensions were primarily governed by feed-per-tooth, with higher feeds minimizing burr size. The study provides actionable insights into optimizing machining parameters for cutting Ti6Al4V, highlighting the trade-offs between force reduction, surface texture, and burr control. These findings contribute to advancing ultrasonic-assisted micro-milling for industrial applications, namely aerospace and biomedical applications requiring high precision and extended tool life.
AB - The current study focuses on axial ultrasonic vibration-assisted micro-milling as an advanced technique to improve the machining performance of Ti6Al4V, a material whose difficult-to-cut properties present a significant barrier to manufacturing the high-quality micro-components essential for aerospace and biomedical applications. A full factorial design was employed to evaluate the influence of feed-per-tooth (fz), axial depth-of-cut (ap), and ultrasonic vibration on cutting forces, surface roughness, burr formation, and tool wear. Experimental results demonstrate that ultrasonic assistance significantly reduces cutting forces by 20.09% and tool wear by promoting periodic tool–workpiece separation and improving chip evacuation. However, it increases surface roughness due to the formation of uniform micro-dimples, which may enhance tribological properties. Burr dimensions were primarily governed by feed-per-tooth, with higher feeds minimizing burr size. The study provides actionable insights into optimizing machining parameters for cutting Ti6Al4V, highlighting the trade-offs between force reduction, surface texture, and burr control. These findings contribute to advancing ultrasonic-assisted micro-milling for industrial applications, namely aerospace and biomedical applications requiring high precision and extended tool life.
KW - burr formation
KW - chip thickness
KW - cutting forces
KW - size effect
KW - surface roughness
KW - Ti6Al4V
KW - tool wear
KW - ultrasonic-assisted micro-milling
UR - http://www.scopus.com/inward/record.url?scp=105023119684&partnerID=8YFLogxK
U2 - 10.3390/jmmp9110356
DO - 10.3390/jmmp9110356
M3 - Article
AN - SCOPUS:105023119684
VL - 9
JO - Journal of Manufacturing and Materials Processing
JF - Journal of Manufacturing and Materials Processing
IS - 11
M1 - 356
ER -