Directional-adaptive approach in machining of additively manufactured Inconel 718

Abstract

The anisotropic properties of additively manufactured materials cause variations in surface finish, cutting forces, and machinability due to directional differences in material properties. This creates challenges in tool path selection for five-axis machining to achieve optimal process conditions. Additionally, traditional models and methods for process modelling and simulation often fail, leading to significant errors, as they do not account for material anisotropy. This work investigates the material behaviour during machining of additively manufactured materials, proposes a directional-adaptive flow stress model for accurate process modelling and simulation, and introduces an adaptive tool path selection strategy tailored for milling of additively manufactured materials.