Cutting parameters in the machining of lightweight components manufactured by PBF-LB

Abstract Additive manufacturing, specifically laser-based powder bed fusion (PBF-LB), allows the design and manufacture of lightweight components, through the incorporation of channels or internal reticular structures that result in a part geometry of lower volume and weight. However, these geometric modifications can influence machining behaviour during finishing processes. In this study, the machining performance of thin-walled PBF-LB Inconel 718 components, comparing a fully solid geometry with three lightened designs featuring internal channels at varying inclinations (60°, 90°, and 120°), was analyzed. Experiments were conducted under diverse cutting conditions to evaluate cutting forces, accelerations, and surface integrity. Key results demonstrated that lightened geometries attenuate cutting stresses more effectively than solid walls, remaining the internal microstructures during the machining processes. These findings validate that PBF-LB internal microstructure designs can enhance machinability, offering a viable strategy for high-performance applications requiring weight reduction and superior surface quality.