Surface Quality of TC4 Machining Based on Synergistic Regulation by Surface Modification and Micro-texture Technology

TONG Xin; WANG Baiyi; YANG Shucai; LIU Feng; ZHANG Jinwei

doi:10.16490/j.cnki.issn.1001-3660.2026.16.005

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Surface Technology ›› 2026, Vol. 55 ›› Issue (16) : 54-65. DOI: 10.16490/j.cnki.issn.1001-3660.2026.16.005

Special Topic—Precision Machining of Difficult-to-Machine Materials

Surface Quality of TC4 Machining Based on Synergistic Regulation by Surface Modification and Micro-texture Technology

TONG Xin, WANG Baiyi, YANG Shucai^*, LIU Feng, ZHANG Jinwei

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Abstract

TC4 titanium alloy is widely used in high-end manufacturing fields such as aerospace and marine equipment due to its low density, high specific strength and excellent corrosion resistance. However, the material features low thermal conductivity and strong chemical activity. When machined by ball-end milling cutters, severe tool-workpiece interfacial adhesion, high cutting loads, obvious machining vibration and unstable surface quality frequently occur, which greatly restricts its high-efficiency and precision machining. To address the above processing challenges, the work aims to propose a synergistic regulation method combining workpiece surface modification and micro-textured ball-end milling cutters. By optimizing the friction, adhesion and contact state of the cutting interface from both the workpiece substrate and cutting tool sides, the milling stability and machined surface quality of TC4 titanium alloy were effectively improved. Three surface treatment processes, namely chemical medium modification, pulsed ion sulfurization modification and active medium coating modification, were adopted to treat TC4 titanium alloy. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) were employed to characterize the microscopic morphology and elemental distribution of different modified layers. Combined with 75 consecutive milling force tests, the effects of various modification methods on cutting interface behaviors and the evolution of milling force were systematically investigated. The experimental results showed that the average milling force of unmodified TC4 titanium alloy after 75 machining cycles was 162.54 N. After chemical medium modification and pulsed ion sulfurization modification, micron-scale corrosion pits and sulfur-rich lubricating layers were formed on the workpiece surface respectively. The average milling forces decreased to 145.25 N and 143.73 N, with reduction rates of 10.64% and 11.57% in comparison with the base material. Through graphene coating modification, a continuous two-dimensional layered lubricating film formed on the titanium alloy surface, which isolated the direct contact between tool and workpiece and delivered outstanding friction reduction via interlayer sliding. It achieved the optimal force reduction effect, with an average milling force of only 140.17 N and a reduction of 13.76% relative to the unmodified specimens. On the basis of the optimized graphene-coated workpieces, orthogonal milling tests were carried out with micro-textured ball-end milling cutters. The effects of texture diameter, texture spacing, laser power, scanning speed and scanning times on the machined surface quality were emphatically analyzed. The research revealed that the micro-textures on the tool surface could store lubricating medium, accommodate fine wear debris and reduce the contact area between tools and chips, forming a favorable synergistic effect with the graphene modified layer. Within the range of selected parameters in this experiment, the minimum surface roughness of the machined workpiece reached 0.279 μm. Mechanism analysis indicated that workpiece surface modification could effectively weaken interfacial adhesion and reduce frictional resistance between tool and workpiece, while tool micro-textures further optimized the tool-chip contact mode and improved the retention condition of lubricating medium. The synergistic effect of the two technologies can significantly suppress the fluctuation of milling force, alleviate surface scratching and adhesive damage, and comprehensively improve the overall machining performance of TC4 titanium alloy during ball-end milling. This work provides a feasible technical solution and experimental reference for the low-load and high-quality cutting of difficult-to- machine titanium alloys.

Key words

TC4 titanium alloy / surface modification / micro-texture / graphene coating / milling force / interface friction reduction / surface quality

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TONG Xin, WANG Baiyi, YANG Shucai, LIU Feng, ZHANG Jinwei. Surface Quality of TC4 Machining Based on Synergistic Regulation by Surface Modification and Micro-texture Technology[J]. Surface Technology. 2026, 55(16): 54-65

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