Sustainability assessment of electron beam melted Ti6Al4V machining: energy consumption and lubricant use

Electron Beam Melting (EBM) is typically used to produce high performance titanium parts, but it falls short in ensuring the high surface finishing always requested for aerospace applications, and this leads to the need of a post-building finishing resulting in additional resources and energy consumption. An optimization of the post-processing is necessary and the literature lacks guidelines in this regard. In this study, 18 cylindrical samples were produced by EBM and then postprocessed by wet and dry turning by using the same process parameters. Surface roughness, tool wear rate, specific cutting energy and energy consumption were investigated and compared to understand the best compromise to remove the same total depth of cut (2.4 mm). Results showed that dry turning can result in saving up 9% in total energy consumption. Also, feed rate and depth of cut can be varied by fixing the spindle speed without significantly affecting surface roughness by saving up to 73% in total energy consumption.