Tool wear and surface roughness characteristics in sustainable machining of additively manufactured titanium alloys

Titanium is widely acknowledged as a challenging metal due to its inherent characteristics. Manufacturers often encounter challenges such as tool wear, reduced tool lifecycle, and increased cutting heat when working with Ti64. This research investigates the cutting characteristics of additively manufactured (AMed) Ti64 under dry cutting, Minimum Quantity Lubrication (MQL), Cryogenic Carbon dioxide (CO2), and a hybrid approach combining MQL and CO2 conditions. Surface roughness, flank wear, temperature, chip morphology, and microhardness were analyzed to assess the impact of cooling strategies. Results indicate that the hybrid approach outperforms individual methods, showing superior surface finish and reduced tool wear. Machined Surface roughness (Ra) measurements reveal a substantial improvement in the hybrid condition, reducing Ra values by 62.44–67.02%, 35.65–41.38%, and 18.68–27.59% compared to dry, MQL, and CO2. Tool wear assessments exhibit significantly lower flank wear values in the hybrid condition, emphasizing the synergistic benefits of lubrication and cryogenic cooling. This research provides valuable insights into tailoring cooling strategies for optimal precision in machining AMed-Ti64 material, which is crucial for achieving high-quality manufacturing outcomes.