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High-speed milling of titanium alloys is widely used in aerospace industries for its high efficiency and good quality of product. The paper empirically studies surface roughness, topography and microhardness variations in high speed milling of Ti6Al4V alloy. The experiments were conducted under minimum quantity lubrication environment. Carbide end mill tool with TiAlN coating and 6 millimeter diameter was used. Full factorial method was used to design of experiments and analyze the effect of machining parameters including cutting speed and feed rate on surface roughness, topography and microhardness. The other cutting parameters i.e. axial depth of cut and radial depth of cut were constant. The results showed that a high quality surface with roughness of 0.2 µm can be obtained by using high speed machining method. Also, microhardness variations versus cutting speed has two-fold nature. It indicates that firstly, by increasing cutting speed up to 375 m/min, microhardness increases and after that, it declines remarkably. In addition, by increasing feed rate, surface microhardness rises and the maximum microhardness was obtained in cutting speed of 375 m/min and feed rate of 0.08 mm/tooth, which showed 57% increase in regard with hardness of the base material. The Images of surface topography showed that increasing of the cutting speed has a significant effect on reduction of surface tears and smears.

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The development of reliable numerical tools for predicting the integrity of machined surfaces is significant. This paper introduces a new customized FE model to predict the deformation during turning of electron beam fused (EBM) Ti6Al4V alloy under dry cutting. The needle microstructure and exotic nano-hardness types of materials are modeled and implemented using a user subroutine in the FE model. The developed FE model provides the possibility of predicting the microstructure (thickness of alpha lamella), the changes in nano-hardness caused by machining operations in dry conditions.

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Titanium and its alloys, especially the Ti6Al4V alloy, have many uses in the aerospace and medical industries due to their unique properties. The production of Ti6Al4V alloy by additive method has been very much considered due to the characteristic of this method. But due to the fact that these parts also require final machining. As a result, it is very important to achieve optimal parameters from a faster and more economical method. In this article, simulation of cryogenic machining of EBM Ti6Al4V alloy in order to study microstructural changes. done. It was validated by comparing the experimental results and simulation of the material model. Then, using the validated FE model, the effects of shear speed on forces, thermal loads and microhardness were discussed.