The improvement of machinability during laser-assisted milling of Ti-6Al-4V alloy was investigated. The effects of laser processing and milling parameters on cutting forces and tool wear have been examined. It is found that local heating and softening of the workpiece by the laser beam in front of the cutting tool significantly reduced the cutting forces, especially the force in the feed direction during up-cut milling. Laser power, tool–beam distance, depth of cut and cutting speed are the parameters influencing the change of feed force during laser-assisted milling. Analysis of the workpiece temperature rise due to laser beam heating shows that the feed force is strongly dependent on the workpiece temperature in front of the cutting zone; significant reduction of feed force occurred when the temperature in front of thecutting zone was in the range 200–450°C. Edge chipping is found to be the tool failure mode for both conventional milling and laser-assisted milling. A significant improvement in tool life during laser-assisted milling was obtained when the workpiece temperature in front of the cutting zone was at an optimum value. Compressed air was used to remove the chip from the cutting tool, which made the milling process more effective. The optimum workpiece temperature in front of the cutting zone with compressed air delivered through the spindle is about 350°C, higher than that with compressed air delivered through a stationary nozzle (about 230°C). The maximum tool life in the former case is much longer than that in the latter case.
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