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

Thanongsak Thepsonthi, Tugrul Ozel

Research output: Contribution to journalConference articlepeer-review


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.

Original languageEnglish (US)
Pages (from-to)158-167
Number of pages10
JournalTransactions of the North American Manufacturing Research Institution of SME
Issue numberJanuary
StatePublished - 2014
Event42nd North American Manufacturing Research Conference 2014, NAMRC 2014 - Detroit, United States
Duration: Jun 9 2014Jun 13 2014

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


  • Decision support system
  • Micro-end milling
  • Multi-objective particle swarm optimization
  • Titanium alloys


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