3C Electronics Titanium Alloy (Ti-6Al-4V) Machining : Side Milling

🕜 Efficiency - 3x higher | 📈 Quality - cutting force/heat reduced, Sa < 0.3µm | ⚙️ Tool Life - chips became smaller and easier to break

What makes Titanium Alloy difficult to machine?


The good ductility and work hardening properties of titanium alloy have brought serious concerns for the surface quality and tool life.  If the cutting force and cutting heat are not well-controlled, the hardened surface and cutting chips will cause severe damages to both the surface quality of workpiece and the cutting tools. 

The work hardening property of titanium alloy when it is heated has brought huge difficulties in the side milling process.  With the protective oxide layer on the surface of titanium alloy, the cutting tools may receive huge cutting force and encounter risks of tool breakage.  Along with the hardened cutting chips, not only the surface quality of workpiece is at stake, but also the tool life will be disastrously unstable. 

 

 

☑️ Titanium Alloy Machining Information

 
    Titanium Alloy Machining Information          
  Material   Titanium alloy (Ti-6Al-4V)
  Feature   Ap 8mm, Ae 0.03mm
  Process   Side milling  
  Ultrasonic Tool Holder        BT30-R01-10
  Rotating Speed   16,000 ~ 20,000 rpm
  Machine Tool Type   C type vertical machining center


 
ultrasonic-assisted side milling on Titanium Alloy workpiece
(Figure 1. ultrasonic-assisted side milling on Titanium Alloy workpiece)


BT-30 ultrasonic toolholder was used on Titanium Alloy side milling
(Figure 2. BT-30 ultrasonic toolholder was used on Titanium Alloy side milling)

 

HIT's Goal in Machining Titanium Alloy


The goal is to improve tool life under higher machining efficiency, while maintaining high surface quality which meets client's requirement.


 

Ultrasonic-Assisted Machining Titanium Alloy Results

 

Titanium Alloy Side Milling : Machining Efficiency

HIT's ultrasonic-assisted machining technology allowed to raise the cutting speed 3 times faster than that without ultrasonic, resulting in the increase in feed rate and machining efficiency.

 

Titanium Alloy Side Milling : Workpiece Quality


comparison of titanium alloy side milling workpiece surface quality between HIT ultrasonic and non ultrasonic
(Figure 3. comparison of titanium alloy side milling workpiece surface quality between HIT ultrasonic and non ultrasonic)
 

The high-frequency ultrasonic micro-vibration helped reduce the cutting heat, and achieved Sa < 0.3µm, which met with client's requirement on the surface quality.

 

Titanium Alloy Side Milling : Tool Life


comparison of tool wear on the rake face between HIT ultrasonic and non ultrasonic machining on titanium alloy side milling
(Figure 4. comparison of tool wear on the rake face between HIT ultrasonic and non ultrasonic machining on titanium alloy side milling)


comparison of shape of chips between HIT ultrasonic and non ultrasonic machining on titanium alloy side milling
(Figure 5. comparison of shape of chips between HIT ultrasonic and non ultrasonic machining on titanium alloy side milling)


the Taylor Tool Life Curve shows the potential improved tool life with HIT ultrasonic machining on titanium alloy side milling
(Figure 6. the Taylor Tool Life Curve shows the potential improved tool life with HIT ultrasonic machining on titanium alloy side milling)


The chips appeared to be larger and very difficult to break in conventional machining.  Along with the cutting heat, chips were repeatedly adhesive to tool's rake face, causing breakage on the tool blade.

The high-frequency micro-vibration of HIT's ultrasonic-assisted machining technology helped reduce cutting force and cutting heat, preventing the residual chips from stucking on the tool/workpiece.  It also allowed the chips to break easily with no entangled chips.


 

HIT Ultrasonic Machining Technology Achievements


🕜 Efficiency - 3 times faster than that without ultrasonic 
📈 Quality - cutting force/heat reduced, Sa < 0.3µm
⚙️ Tool Life - chips became smaller and easier to break, preventing residual chips from stucking on the tool

💰 With the enhanced machining efficiency and improved tool life, the production capacity can be greatly increased.



 

Titanium Alloy Machining in Industry Application


Side milling Titanium Alloy is often applied in the 3C Electronics industry, Biomedical industry, and Automotive (electric vehicle) industry, especially for titanium bone plate, artificial joint, smart wearable device (Apple watch ultra bezel), and the underbody of Tesla Model S, etc.


Titanium alloy (Ti-6Al-4V) is rated approximately 41HRC for its hardness, which is not as hard compared to other metal alloys.  It offers a combination of lightweight, high strength, low density, good corrosion resistance and ductility.

The excellent material properties of titanium alloy, including lightweight, high strength, good corrosion resistance and good ductility, make it the prime choice for many fields of applications.  

Being non-toxic is also one of its excellent material attributes that allows it to be an ideal material for bone plates and artifical joints in biomedical industry.  Titanium alloy is also anti-fingerprint and resistant to stain, which makes it suitable for smartphone phone case or the bezel of smart wearable devices.  Its resistance to heat and high strength also allows it to be one of the perfect materials for the underbody of Tesla Model S to protect the battery from any roadside force or piercing. 

HIT's Ultrasonic Machining Module offers a comprehensive solution in machining these difficult-to-cut materials.  With the assistance of HIT's Ultrasonic Machining Technology, clients stopped worrying about poor surface quality and tool life.  Not only the surface quality and tool life can be improved, but the machining efficiency can also be greatly enhanced.  HIT assures its clients of matching up with their requirements and achieving even better outcomes!



💡 Learn more about Titanium Alloy Machining cases

💡 Introduction on Titanium Alloy Machining