Modeling of cutting force in micro-end-milling process with experimental validation on additive manufactured Nickel-based superalloy

Abstract Nowadays aerospace, microelectronics, biotechnology industries require small sized components with complex shape and high mechanical properties, often operating in aggressive environment. In this framework, Additive Manufacturing (AM) of Nickel-based superalloys is an interesting and cost effective process. Fewer design constraints and the weight reduction achievable through the topology optimization are the most relevant AM advantages. Furthermore, micro-scale features on the additively fabricated parts can be manufactured by using micro machining. Subtractive processes ensure to achieve high-precision mechanical coupling due to better surface finishes and tighter tolerances. A lack of scientific studies focusses on the material removal behavior of difficulty-to-cut alloys produced via Additive Manufacturing is evident. This work describes a machining analytical force models which considers the presence of ploughing- and shearing- dominated cutting regimes. The undefined cutting force model parameters and the Minimum Uncut Chip Thickness (MUCT) can be identified through proper experimental tests. The refinement procedure of the model was utilized to characterize Inconel 625 samples fabricated by LaserCUSINGTM. The cutting force data were elaborated with an iterative methodology based on a search algorithm. The model successfully predicted how the cutting force changes as a function of the process parameters.