@article{d8fa8974-b847-4264-b8a9-7daef181ba07,
  abstract     = {{<p>When machining titanium alloys, diffusion and oxidation are key wear mechanisms that affect conventional machining. At the microscale, however, the knowledge about tool-workpiece interactions remains limited, partly due to the challenge of analysing wear phenomena in microtools. This study investigates tool wear mechanisms during micromilling of Ti6Al4V by employing cross-sectional analysis of worn tools using both electron probe micro analysis and backscattered electron imaging. Micromilling tests were performed comparing CrAlN coated and uncoated tools at different machining lengths. Machining forces, surface integrity, and chip formation were assessed to characterise the process behaviour. Additionally, a finite element model was developed to estimate parameters that are difficult to measure experimentally, including local temperature, tool-workpiece contact pressure, and residual stresses, enabling further interpretation of the observed wear patterns. Results reveal that, whereas diffusion-driven wear dominates in conventional machining, under the investigated conditions, microtools are primarily affected by mechanical stresses, emphasising the important role of coating strength. Tungsten carbide grains at the cutting-edge fracture under high contact pressures (∼10 GPa) and are progressively removed with the chips, driving coating delamination and adhesive wear, while moderate process temperatures (∼250°C) explain the negligible role of chemical or thermal effects such as diffusion wear. Surface integrity analysis shows that subsurface features and residual stresses are highly sensitive to wear-induced changes in tool geometry, which in turn cause microstructural effects such as compressive residual stresses beneath the surface. These findings emphasise fundamental differences between micro- and macro-scale machining and provide guidance for tool design and process optimisation in micromilling.</p>}},
  author       = {{Gonçalves, Maria Clara Coimbra and Lindvall, Rebecka and Yadav, Rahul and Mandazhiev, Mihail and Alsters, Rob and Bushlya, Volodymyr and M’Saoubi, Rachid and Ghadbeigi, Hassan}},
  issn         = {{0924-0136}},
  keywords     = {{FE simulation; Micromilling; Ti6Al4V; Tool wear}},
  language     = {{eng}},
  publisher    = {{Elsevier}},
  series       = {{Journal of Materials Processing Technology}},
  title        = {{Adhesion-induced tool degradation in micromilling of Ti6Al4V : Cross-sectional microanalysis and process mechanics correlation}},
  url          = {{http://dx.doi.org/10.1016/j.jmatprotec.2026.119383}},
  doi          = {{10.1016/j.jmatprotec.2026.119383}},
  volume       = {{354}},
  year         = {{2026}},
}