Technological and sustainability implications of wet and dry turning of Ti6Al4V EBM parts
COZZOLINO Ersilia, FRANCHITTI Stefania, BORRELLI Rosario, PIROZZI Carmine, ASTARITA Antonellodownload PDF
Abstract. Sustainability is a crucial topic nowadays and Additive Manufacturing (AM) processes are becoming more and more widely used today also because, among its advantages, is claimed to be green technology. However, AM parts usually require postprocessing to improve their surface finishing and result assemblable. In this study, a Ti6Al4V cylindrical sample has been manufactured by Electron Beam Melting (EBM) and then post-processed by turning. Both dry and wet turning has been performed by using the same process parameters. Surface roughness has been measured both before and after each turning pass along the parallel and perpendicular direction to the cylindrical axis and energy consumption has been recorded during each turning pass. Results showed that both dry and wet turning led to a lower roughness along the perpendicular direction to the cylindrical axis than that along the parallel direction, as a result of the technological signature of the turning process. Also, they depict that the first turning pass results in higher cutting forces and, then, the highest values of energy consumption among all the turning passes, both in wet and dry turning. The Specific Energy Consumption (SEC) index has been investigated to evaluate the energy required to remove a unit volume of material; it reflects lower cutting efficiency in the material removal process.
Sustainable Manufacturing, Additive Manufacturing, Machining, Turning, Roughness, Electron Beam Melting
Published online 4/19/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: COZZOLINO Ersilia, FRANCHITTI Stefania, BORRELLI Rosario, PIROZZI Carmine, ASTARITA Antonello, Technological and sustainability implications of wet and dry turning of Ti6Al4V EBM parts, Materials Research Proceedings, Vol. 28, pp 1939-1946, 2023
The article was published as article 209 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
 S. Pawanr, G.K. Garg, Selection of optimum Cutting Parameters for Minimization of Specific Energy Consumption during Machining of Al 6061, J. Phys. Conf. Ser. 1240 (2019). https://doi.org/10.1088/1742-6596/1240/1/012064
 Y.H. Çelik, E. Kilickap, M. Güney, Investigation of cutting parameters affecting on tool wear and surface roughness in dry turning of Ti-6Al-4V using CVD and PVD coated tools, J. Brazilian Soc. Mech. Sci. Eng. 39 (2017) 2085-2093. https://doi.org/10.1007/s40430-016-0607-6
 M. Younas, S.H. Imran Jaffery, M. Khan, R. Ahmad, L. Ali, Z. Khan, A. Khan, Tool Wear Progression and its Effect on Energy Consumption in Turning of Titanium Alloy (Ti-6Al-4V), Mech. Sci. 10 (2019) 373-382. https://doi.org/10.5194/ms-10-373-2019
 Standard Test Method for Apparent Density of Free-Flowing Metal Powders Using the Hall Flowmeter Funnel, in: ASTM VOL 02.05.
 M. Koike, K. Martinez, L. Guo, G. Chahine, R. Kovacevic, T. Okabe, Evaluation of titanium alloy fabricated using electron beam melting system for dental applications, J. Mater. Process. Technol. 211 (2011) 1400-1408. https://doi.org/10.1016/j.jmatprotec.2011.03.013
 V. Upadhyay, P.K. Jain, N.K. Mehta, In-process prediction of surface roughness in turning of Ti-6Al-4V alloy using cutting parameters and vibration signals, Meas. J. Int. Meas. Confed. 46 (2013) 154-160. https://doi.org/10.1016/j.measurement.2012.06.002
 E. Cozzolino, A. Astarita, R. Borrelli, S. Franchitti, V. Lopresto, C. Pirozzi, A Preliminary Investigation of Energy Consumption for Turning Ti6Al4V EBM Cylindrical Parts, Key Eng. Mater. 926 (2022) 2355-2362. https://doi.org/10.4028/p-vm4f1y
 E. Cozzolino, V. Lopresto, D. Borrelli, A. Caraviello, An integrated approach to investigate the energy consumption for manufacturing and surface finishing 3D printed Inconel 718 parts, J. Manuf. Process. 79 (2022) 193-205. https://doi.org/10.1016/j.jmapro.2022.04.045
 M. Mangiaterra, Lubricants impact on cutting forces, Degree Project In Mechanical Engineering, Second Cycle, KTH Royal Institute of Technology, Sweden, 2018.
 G.M. Królczyk, M. Wzorek, A.Król, O. Kochan, J. Su, J. Kacprzyk, Sustainable Production : Novel Trends in Energy, Environment and Material Systems Studies in Systems, Decision and Control 198, Springer Cham, 2019. https://doi.org/10.1007/978-3-030-11274-5