Study on the Tool Wear and Surface Integrity in Induction-Assisted Milling of γ-TiAl Alloys

The γ-TiAl alloy is widely used in aerospace and energy industries due to its excellent high-temperature stability and lightweight properties. However, its poor machinability often leads to suboptimal surface quality and significant tool wear. Induction-assisted milling, which introduces high-frequency inductive heating, enhances the material’s plasticity and reduces cutting forces, thereby improving milling performance. This study experimentally compares the effects of conventional milling and induction-assisted milling on the surface integrity and tool wear of γ-TiAl alloys under different material removal rates. The results demonstrate that by selecting appropriate milling parameters induction-assisted milling can reduce cutting forces by over 20%, decreases surface roughness by more than 30%, and significantly improves the surface quality of γ-TiAl alloys, with no significant increase in tool wear. This research offers valuable experimental and theoretical insights for the application of induction-assisted milling in the machining of difficult-to-machine materials.