Experimental investigation of top burr formation in high-speed micro-end milling of titanium alloy

Superalloys with burr-free parts are most preferably used in biomedical, aerospace, marine and automotive applications. In order to reduce the global pollution content, industries strive to execute stringent green manufacturing technologies. There is a need to investigate the different available tools in high-speed micro-milling process to achieve desired burr free with good surface finish on super alloys without using traditional coolants. In machining of titanium and its alloys, because of low thermal conductivity and reactivity with tool materials instigate the burr formation on work material and lowers the tool performance. The main objective of this article is to investigate the top burr formation in high-speed micro-end milling of alpha + beta-titanium alloy-grade 23 ELI (Ti-6Al-4V) under dry cutting conditions using Uncoated and physical vapor deposition coated AlTiN, TiAlN tungsten carbide end mills. Machining performance of the three cutting tools was compared. From the comparison of cutting tools for machining titanium alloy-grade 23, it is found that coated TiAlN tools produce less burr formation than coated AlTiN and uncoated tungsten carbide tools.