A comprehensive experimental investigation on the correlation between chip formation, machined surface integrity, and particle emissions during high-speed milling of TC4 titanium alloy

In today’s industry, machining processes must not only meet technical and economic requirements but also prioritize sustainability in terms of environmental impact and operator safety. Recently, particle emissions have gained significant attention due to their detrimental effects on the environment, operator health, workpiece quality, and energy efficiency. Hence, the current research aims to investigate particle emissions, their correlations with machining parameters, and machined part surface integrity. First, high-speed milling (HSM) experiments were conducted under various cutting parameters in a dry environment, and the effect of cutting parameters on chip formation, machined subsurface microstructure evolution, burr formation, particle emissions, and surface roughness was analyzed. The experimental results revealed that parameters such as cutting speed initially increased chip serration, deformed layer thickness, particle emissions, and surface roughness, followed by a subsequent decrease. In contrast, it consistently increased with feed rates and depth of cuts. Finally, the correlation between particle emissions and machined surface integrity was obtained and discussed. The current research can provide more valuable insights for designing sustainable and safe machining processes that balance efficiency with reduced environmental impact and improved operator safety.