Jixiong Fei

Metal additive manufacturing processes such as selective laser melting (SLM), laser powder bed fusion (L-PBF), electron beam melting (EBM) and laser metal deposition (LMD) can produce additively manufactured nearly fully dense parts with high geometrical complexity. These are often used as components in automotive, aerospace and medical device industries. Finish machining of these components is required to achieve the desired surface finish and dimensional tolerances. The investigations on additively manufactured alloys, as reported in the literature, indicate that a layer-wise scan strategy (orthogonal or layer-to-layer rotation) and process parameters have significant influences on the resultant microstructure which affects the final mechanical properties and fatigue life. The solidification microstructure depicts that growth directions of columnar grains and sizes of cellular grains that are affected by the layer-wise scan strategy. This paper presents experimental investigations on finish milling parameters on a nickel-based alloy manufactured with L-PBF using two distinct layer-wise scan strategies. The results reveal some effects of milling direction against the layer-wise build direction. The effects of cutting speed and feed rate on resultant cutting forces, chip formation, as well as surface finish at various cutting orientations in nickel-based alloy workpieces are reported.