Analytical modeling of micro-milling operations on biocompatible Ti6Al4V titanium alloy

Among the biocompatible materials, Ti6Al4V titanium alloy is widely spread due to its properties, such as corrosion and fatigue resistance combined with low density. can be processed by Additive Manufacturing technologies, Power Bed Fusion (PBF). The biomedical applications require good surface finishing ensure biocompatibility tissues organs. Machining an adequate process final roughness of components. necessity realize miniaturized features implicates usage micro mills diameter lower than one millimeter. It several issues, size effects, higher expected cutting forces, rapid tool wear which addressed experimental tests modeling. This work reports results micro-milling performed on additively manufactured samples in Ti6Al4V. PBF was utilized manufacture employing laser source (PBF-LB). machining center equipped a loadcell acquire force signal. An analytical model calibrated data purpose predicting loads considering ploughing- shearing- regimes. Specific were calculate Minimum Uncut Chip Thickness (MUCT) calibrate unknow parameters model, while further allowed verify reliability about prediction. elaboration iterative methodology based Particle Swarm Optimization (PSO) algorithm.