Articles | Volume 17, issue 1
https://doi.org/10.5194/ms-17-427-2026
https://doi.org/10.5194/ms-17-427-2026
Research article
 | 
15 Apr 2026
Research article |  | 15 Apr 2026

Multiphysics investigation of thermo-mechanical behavior and mechanisms in small-hole tapping of Ti6Al4V alloy

Wei Gao, Xinfu Liang, Lei Lin, Xiangkun Meng, Wenjing Zhang, Qi Gao, and Jiawei Zhang

Cited articles

An, Q., Cai, C., Zou, F., Liang, X., and Chen, M.: Tool wear and machined surface characteristics in side milling Ti6Al4V under dry and supercritical CO2 with MQL conditions, Tribol. Int., 151, 106511, https://doi.org/10.1016/j.triboint.2020.106511, 2020. 
Bai, D., Sun, J., Chen, W., and Wang, T.: Wear mechanisms of WC/Co tools when machining high-strength titanium alloy TB6 (Ti-10V-2Fe-3Al), Int. J. Adv. Manuf. Technol., 90, 2863–2874, https://doi.org/10.1007/s00170-016-9607-z, 2017. 
Barooah, R. K., Paiva, J. M., Arif, A. F. M., Rawal, S., Bose, B., and Veldhuis, S. C.: Investigation on wear mechanisms of PVD coatings for form taps in threading of Al–Si alloy, Wear, 464–465, 203528, https://doi.org/10.1016/j.wear.2020.203528, 2021. 
Biermann, D. and Oezkaya, E.: CFD simulation for internal coolant channel design of tapping tools to reduce tool wear, CIRP Ann., 66, 109–112, https://doi.org/10.1016/j.cirp.2017.04.024, 2017. 
Brandão, G. L., Silva, P. M. D. C., De Freitas, S. A., Pereira, R. B. D., Lauro, C. H., and Brandão, L. C.: State of the art on internal thread manufacturing: a review, Int. J. Adv. Manuf. Technol., 110, 3445–3465, https://doi.org/10.1007/s00170-020-06107-x, 2020. 
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Short summary
To create reliable tiny threads in tough titanium for aerospace parts, this research used advanced computer simulations. We found that friction generates most of the tool stress and intense localized heat, which explains rapid tool wear. These insights help design better tools and optimize machining settings, improving manufacturing efficiency and product durability for critical engineering applications.
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