Modelling of machining induced damage in Additively Manufactured aerospace parts

Additive Manufacturing techniques have attracted many attentions in the aerospace and automotive industries. This is due to the provided flexibility to generate complex geometrical features in the manufactured components. However, poor surface quality and dimensional accuracy are the main disadvantage for the components fabricated by these methods. The lower surface finish on the manufactured components makes it often necessary to machine the final products for engineering applications. The proposed research aims to utilise advanced modelling techniques to develop a predictive Finite Element model of chip formation and machining induced damage in machining of AM build parts. This will also include an investigation into the machinability of the AM components and the effect of built parameters on the subsurface damage and chip formation mechanism. Different components with various set of parameters are manufactured and machining experiments with a range of cutting parameters are designed. The effect cutting conditions on the surface characteristic and subsurface damage will then be studied using Scanning Electron Microscopy the microgrids techniques. The predicted results will be validated using the experimental findings and the outcome will be used to develop a more robust manufacturing approach for complex parts for aerospace applications.