Comparative evaluation of milling performance of AlSi10Mg samples fabricated via selective laser melting and casting

This study examines cutting forces, tool wear, and chip formation during the milling of AlSi10Mg test samples produced via selective laser melting (SLM) and sand casting. Five samples each were produced using both sand casting and SLM, and a total of 10 samples were tested under various cutting speeds and depth of cut values. Due to their dense and fine-grained microstructures, SLM samples exhibit higher cutting forces; however, they produce shorter and more regular chips, which reduces chip adhesion during machining and facilitates chip control. On the other hand, cast samples, with their softer and more heterogeneous structures, have lower cutting forces, producing longer and continuous chips. In both cast and SLM samples, increasing spindle speeds and decreasing cutting depths lead to reductions in cutting forces, chip adhesion, and tool wear.