Functional design and testing of additively manufactured milling cutting heads with enhanced structural and lubrication properties

Abstract This paper describes the redesign of a face milling cutting head specifically for additive manufacturing (AM) production. The functional and structural properties were modeled and experimentally characterized for the modified version of the original component. Typically, this type of component is fabricated using subtractive processes and is characterized by its heavyweight, high torsional and compressive stiffness, and several coupled parts. Additionally, the component includes an integrated lubrication system composed of straight channels. In this study, laser powder bed fusion (L-PBF) was used to evolve the tool toward a lightweight design. The modified version consists of a single body in Ti6Al4V alloy, with a 33.9% mass reduction, lower displacements at the cutting tips, and a lower maximum stress value (− 12.2%). Furthermore, the use of parabolic-shaped channels allows the rotation of the tool to improve the lubricant flow at a uniform pressure and velocity, resulting in more refined spraying and cooling performances. The redesign also takes into account the process constraints and process-related features.