Impact of cutting force dynamics on machined surface integrity of maraging steel lattice structures manufactured by selective laser melting
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Opole University of Technology, ul Mikołajczyka 5, 45-271 Opole, Poland
Corresponding author
Piotr Niesłony
Opole University of Technology, ul Mikołajczyka 5, 45-271 Opole, Poland
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ABSTRACT
The research presented aimed to evaluate the machinability and cutting force dynamics of Maraging Steel lattice structures manufactured via SLM technology compared to a monolithic solid reference. Face turning operations were conducted at relative densities of 30, 40, and 50% alongside a 100% solid baseline to systematically analyze the effect of a continuous linear decrease in vc on the Fc, Ff, and Fp components and on the resulting surface integrity. The study reveals that the inherent porosity of the lattice matrix transforms continuous shearing into a harsh, intermittent cutting regime, inducing severe elasto-plastic yielding and massive relative force fluctuations at low vc. Furthermore, a critical technological resonance zone was identified at intermediate vc values from 364.60 to 174.47 m/min, where kinetic force spikes, primarily driven by the Ff dynamics, directly translated into violent structural tearing and maximum surface roughness. A profound density-resistance paradox was also observed, in which localized strain hardening within the topological voids led the less dense lattice architectures to exhibit a significantly higher median Fp than the solid material. Ultimately, the experimental findings establish a critical technological guideline for industrial applications, demonstrating that maximizing vc effectively overpowers the lattice's inherent structural compliance, completely suppressing dynamic chatter and ensuring superior geometric integrity of the machined struts.