Magnetic field assisted micro-milling of selective laser melted titanium alloy

Abstract

Selective Laser Melting (SLM) is one of the additive manufacturing technologies for producing titanium alloy parts. Following SLM, micro-milling is critical to achieving good surface quality of the fabricated part. This study examines the impact of a magnetic field on the micro-milling of SLM Ti6Al4V, aligning with existing theories that suggest its advantages. Comparative experiments demonstrate a 22 % reduction in average surface roughness when using a magnetic field. The study also explores the transverse distribution of surface roughness in magnetic field-assisted micro-milling. SEM images confirm fewer surface defects, such as welded chips, material side flow, deep feed marks, and microparticles. Additionally, the application of a magnetic field significantly reduces tool wear, including built-up edge (BUE), micro-chipping, and adhesive wear. These findings offer valuable insights for employing magnetic fields in the micro-milling of additively manufactured parts.