Experimental investigation of tool wear and surface integrity using a large pulsed electron beam (LPEB) irradiated end-mill cutting tool for Ti-6Al-4 V

Abstract

In advanced industries such as automotive, aerospace, and biomedical, the Ti-6Al-4 V material is widely used owing to its superior mechanical properties. However, because of inadequate thermal properties, tool wear increases rapidly, leading to persistent problems with surface integrity. Therefore, tool wear needs to be enhanced while ensuring the surface integrity during the machining. This paper investigates the surface integrity of Ti-6Al-4 V using a large pulsed electron beam (LPEB) irradiated cutting tool, examining surface integrity from a multiscale (macro, and micro) perspective. The electron beam was irradiated on the cutting tool, and the characteristics analysis of the LPEB-irradiated cutting tool was conducted, including tool surface roughness and edge radius. The flank wear was measured to identify the effect of LPEB irradiation on wear evolution. Furthermore, the influence of the LPEB-irradiated cutting tools on the work material was analyzed compared to the non-irradiated cutting tools; the machined surface roughness was reduced by 13.6 %, the plastic deformation length was reduced by 41.0 %, microhardness was improved by 44.3 %, and the residual stress of the machined surface was reduced by 27.1 %, respectively. This result is caused by the improved surface qualities of the LPEB-irradiated cutting tool in terms of reduced tool surface roughness and increased edge radius. Moreover, the reduced flank wear may positively affect the enhancement of surface integrity.