Design of cutting tools for L-PBF manufacturing and functional performances validation

This paper reports the design of cutting tools for milling specifically addressed to additive manufacturing (AM) with associated validation with experimental tests. Laboratory tests under controlled conditions and operative tests on milling machine are conducted. The modified component is compared to the original version made by subtractive methods. The component includes an integrated lubrication system composed by reservoir chamber and channels. The modified version built with laser powder bed fusion (L-PBF) process has one single body in titanium alloy, with 33.9% mass reduction. The tests provide torsional stiffness validation and local surface strain, used for comparison with design modeling results. The parabolic-shaped channels provides uniform lubricant flow pressure and velocity, with more refined spraying and cooling performances.