Process optimization and decision support for high performance micro-milling of Ti-6A1-4V alloys

Titanium alloys are considered biocompatible and suitable for medical applications. However, mechanical machining of titanium alloys is still very difficult and even more challenging when it comes to micro-scale mechanical machining such as micro-end milling. Severe burr formation and rapid tool wear create significant problems to micro-machining process and finished surfaces. In order to improve the performance of micro-end milling in Ti-6A1-4V alloy, this study proposes a novel method in selecting the optimum process parameters which can meet the micro-machining requirements and constraints. The experiments, finite element simulations, Constrained Multi-Objective Particle Swarm Optimization (CMOPSO) and mathematical modeling techniques were utilized to facilitate the process parameter selection. Based on the machining tests on a circular thin rib feature, the decision support results indicate significant improvements in process performance.