Multi-objective process optimization for micro-end milling of Ti-6Al-4V titanium alloy

Micro-end milling is one of the promising methods for rapid fabrication of features with 3D complex shapes. However, controlling the micro-end milling process to obtain the desired results is much harder compared to that of macro-end milling due to the size effect and uncontrollable factors. The problem is much pronounced when workpiece material is a difficult-to-process material such as titanium-based alloys which are widely used as material of choice for aircraft structures, turbine blades, and medical implants. In order to find the optimal process parameters which minimize the surface roughness and burr formation, experiments were conducted and models obtained with statistically based methods utilized in multi-objective particle swarm optimization to identify optimum process parameters. The results show that the average surface roughness can be minimized while burr formation is reduced concurrently.