A material removal model considering the effect of anisotropy on the processing of laser metal deposition Ti-alloy

The Ti-alloy (Ti6Al4V) displays obvious anisotropism in mechanical properties due to the specialization of laser metal deposition (LMD) processing. As a result of this anisotropism, various processing efficiency and performance are achieved in distinct processing orientations. A material removal rate prediction model is proposed in this work. The model accounts for the material’s anisotropy as well as the impacts of tool settings, cutting forces, and microhardness. Scratch tests on the titanium alloy Ti6Al4V produced by laser deposition were performed to evaluate the model's applicability and validity. The material removal volume change was investigated at five distinct scratch angles with the deposition direction of 0°, 22.5°, 45°, 67.5°, and 90°, and surface morphology and subsurface damage affected the material processing parameters in various directions. analysis. The results demonstrate that the model predicts the material removal rate with good accuracy and applicability, with an optimal error rate of 12.2% and an average error rate of 13.9%. It can be utilized to improve the efficiency of laser deposition processing in the fabrication of titanium alloys. Among these five angles, when the scratch angle is 67.5°, the material removal rate of titanium alloy Ti6Al4V is the highest, which is consistent with the model conclusion. At the same time, the cutting force is the smallest (verified by actual milling test), the surface defects are the least, and subsurface cracks are the least.