Milling tool optimization by topology optimization technique

In milling operations, the weight of the milling tool greatly affects the motion speed of the mandrel, especially when a complex tool path must be performed. Thus, it is essential to realize more lightweight tools, without a significant decrease in the mechanical and production performance. Traditionally, due to the limitation of the conventional manufacturing processes, the design of a new milling tool cannot be too much complex and thus cannot fully satisfy the mentioned goals. Nowadays, thanks to the topology optimization technique and the additive manufacturing (AM) technologies, such as the selective laser melting (SLM), it is possible to realize more complex part geometries to obtain more lightweight and high-performance tools. In this paper, a new design of a milling tool with a weight reduced by 30% is presented; SLM process has been selected to realize the milling tool. In order to minimize the use of support structures, required by the SLM process to correctly realize the desired part, the new geometry has been little modified. A more lightweight milling tool has been produced and every support structure has been successfully removed from the component.