Milling performance evaluation during the machining of additively manufactured Ti6Al4V using textured milling tools under cryogenic cooling

This study examined the machining performance of conventional and textured tools for additively manufactured (AM) Ti6Al4V under various cutting conditions. Results demonstrated that the milling forces were substantially reduced when textured polycrystalline diamond (PCD) tools were used in combination with cryogenic cutting (TPCC), compared with the use of conventional PCD tools with dry cutting (CPDC), conventional PCD tools with cryogenic cutting (CPCC), and textured PCD tools with dry cutting (TPDC). Notably, CPCC provided better improvement in machined surface quality than CPDC, CPCC, and TPDC under the same cutting parameters as a whole. Additionally, cutting under CO 2 cryogenic cooling effectively prevented chip adhesion and reduced the adhesion area are compared with dry cutting using the same tool type. The results also revealed demonstrated that the total cutting force can be reduced by up to 81%, 54%, and 82%, respectively, when using the TPCC compared with that when using CPDC, CPCC, and TPDC on the whole. The underlying machining mechanism was examined in detail, focusing on the influence of the textured tool combined with cryogenic cooling on tool-chip contact length and lubrication performance.