A new layered manufacturing machine with cutting force analysis in tapered end milling

We introduce a new layered manufacturing machine with its associated geometric cutting force model. This machine is designed to build metal parts and is a modified type of commercial layered object manufacturing (LOM) machine. This apparatus uses tapered end mills with different angles instead of laser to cut the layer edges. The proposed machine needs higher stiffness, because cutting action would regularly create more inaccuracy. Consequently, a new force model is considered that takes into account cutting conditions, cutter geometry and combination of tool-workpiece materials. Then, by force and stress analysis cutting-force induced inaccuracy has been evaluated for different components of the machine. Finally, the effectiveness of the machine and its capability to build functional metal parts with different geometries is clearly shown.