Study of burr width and height using ANOVA in laser hybrid micro milling of titanium alloy (Ti6Al4V)

Abstract

Ti6Al4V is regarded as the “workhorse” in aerospace industry for its wide applications at high temperatures. Unique attributes are high strength to density ratio and outstanding material properties at high thermal conditions. This present-day work involves the pre-slotting on Ti6Al4V surface with the help of fibre Laser, followed by the operation of micro-milling on respective Laser engraved slots. Localized melting due to Laser ablation leads to the decrease in the surface contact between milling tool and material surface. Micro-milling in return helps to remove the Heat affected zones (HAZ) created during Laser engraving process. ANOVA helps to point out the contributing factors for burr width and height on both milling sides. Main effect plots generated during process optimization, help to point out optimal combination of input parameters for minimized burr width and height. Higher frequency of Laser helps to generate consistent slots. Lower rotational speeds are responsible for high values of burr width and height. Whereas high rotational speed leads to efficient chip removal, resulting in decreased burr width and height.

Keywords

• Micro-milling
• Burrs formation
• Laser hybrid machining
• Titanium alloy
• Micro cutting
• Process optimization