Investigations on achievable surface quality in milling of Ti-35Nb-7Zr-5Ta alloy

β-type Titanium (Ti) alloy possesses less Young’s Modulus (E), which is significant for manufacturing of medical implants, since it reduces stress shielding effect. In this work, surface quality analysis on Ti-35Nb-7Zr-5Ta(TNZT) alloy was carried out to reveal the osseointegration characteristics. TNZT alloy was fabricated by vacuum arc melting followed by homogenization process. Microstructure analysis with X-ray diffraction spectroscopy study revealed the formulation of body-centered cubic structure in the TNZT alloy. Further high speed milling was carried out to analyze the impact of process variables on surface quality. Parameters include axial depth of cut (ap), cutting velocity (vc), and feed/tooth (fz) are taken into consideration. In general, implants are miniature in size; hence, Carbide flat end mill cutter size of 2 mm is used for investigation. 27 slots are generated under mist cooling condition by using factorial experimental design approach. Surface characteristics and morphology of machined region were examined to discover biocompatibility. It is observed that ‘ap’ and ‘vc’ significantly affect surface quality and lowest Ra of 0.422 µm was observed. It is well within the allowable value between 1 and 1.5 µm for better osseointegration. It is also revealed that microparticle deposition and groove formation intensifies when ‘ap’ is higher at 200 µm.