Machinability of Ti6Al4V alloy produced by electron beam melting under different lubricating conditions

In the last decade, the growing diffusion of metal additive manufacturing technologies is revolutionising the manufacturing processes of the most advanced industrial fields. Nowadays, more and more companies operating in the aeronautic and in the biomedical field are employing the additive manufacturing technology of Electron Beam Melting (EBM) to produce prosthesis and aero engine parts made of the titanium alloy Ti6Al4V, traditionally produced by hot forging and machining. Thanks to this technology, it is possible to realise a complex shape component with tailored mechanical and geometrical properties, passing from the 3D CAD model directly to the near net shape geometry without any intermediate manufacturing steps, thus cutting the production costs. However, finishing machining operations are still necessary to remove the surface porosity that is a direct and inevitable consequence of additive manufacturing technologies, and to achieve higher surface quality and geometrical accuracy. Aiming to optimize the machining operation and to avoid detrimental surface damages left on the final product, the material machinability has to be taken into account. At the moment, many efforts coming from both the academic and industrial research have been spent to enhance the poor machinability of wrought Ti6Al4V alloy due to the increasing demand from the aeronautic field; however no published works and technical data are available regarding the machinability of EBM Ti6Al4V that presents different mechanical properties. Within the biomedical field, the surgical replacements made of Ti6Al4V are traditionally machined under flood coolants, made of synthetic or vegetable oil and water emulsions. As a consequence, costly sterilizing and cleaning operations are performed to remove the toxic and pollutant chemical residuals left on the finished products at the end of the manufacturing process. Thus, there is a need to revise the traditional lubricating strategies applied in machining operations of surgical implants, proposing an innovative solution that might satisfy technological, environmental and economic issues. In this PhD thesis, an innovative cryogenic cooling line has been developed and implemented to turn EBM Ti6Al4V alloy, as a promising alternative to standard cooling methods applied in machining surgical implants. The alloy machinability has been firstly investigated trough an experimental approach, evaluating the effects of three different cooling methods namely: dry, wet and cryogenic and of different cutting parameters, on the tool wear, on the surface integrity and on the chip morphology. Subsequently, a FE numerical model has been developed to simulate the turning operation of EBM Ti6Al4V alloy, capable to predict the effects of different process conditions. Due to the beneficial effects induced by the cryogenic cooling on the surface integrity of turned Ti6AL4V EBM test pieces, the feasibility of such technology for biomedical applications has been validated by means of wear tests: the wear resistance of cryogenically machined specimens clearly increased with a strong reduction of metallic particles loss. Finally, cryogenic turning has been employed to machine real acetabular cups, in comparison with standard cooling methods applied in machining surgical implants. The beneficial effects imparted by cryogenic cooling in terms of improved material machinability, improved wear resistance and satisfying achievable geometrical accuracy, foresee a potential applicability of this technology in the biomedical field for years to come