Thermal analysis of micro milling titanium alloy Ti–6Al–4V

Abstract This article presents an analysis for micro milling of titanium alloy using finite element modeling and experimental validation. Titanium alloys are commonly used in micro tools for surgery as well as in small size biomedical implants such as miniature left-ventricular assist devices (LVAD), finger joint replacements and small bone implants. Titanium alloys are considered as difficult to machine materials due to their thermo-mechanical properties. Prediction of the temperature fields in the workpiece and the tool during micro milling of Titanium is vital. The temperature in the machining not only affects the tool wear, but also directly influences the residual stresses, 3D distortions and the dimensional accuracy of micro parts. This article presents a finite element model to predict tool and workpiece temperature fields in the micro milling process of Ti–6Al–4V under various cutting conditions. Temperature simulations are validated by thermocouple measurements in the micro milling of Ti–6Al–4V.