Innovations
Vol. 14 (2026), Issue 2, pg(s) 58-61

INNOVATIVE SOLUTIONS

Vibration-Based Monitoring of DMLS Ti-6Al-4V Micro-Milling

  • 1 Prototyping and Innovation Centre, Faculty of Mechanical Engineering, Technical University of Košice, Slovakia
  • 2 R&D&I Consortium, Sofia Tech Park, lab. 3D Creativity and RP of New Products Lab; Technical University of Sofia, Sofia, Bulgaria

Abstract

This paper deals with vibration-based monitoring of micro-milling of DMLS Ti-6Al-4V ELI using a SCHUNK iTENDO² smart toolholder. The study evaluates the applicability of vibration signals for assessing process conditions during machining with a 1 mm diameter end mill. Annealed and non-annealed samples were machined under different cutting directions relative to the build layers and different initial surface states. The tests were carried out at constant cutting speed, feed per tooth and depth of cut, while vibration data were recorded continuously. The machined grooves were then evaluated by optical and profilometric methods with emphasis on burr formation and edge quality. The results showed that annealing had the strongest positive effect on process stability, reducing vibration levels and significantly improving edge quality. The lowest burr formation was observed in annealed samples machined perpendicular to the printed layers, whereas the non-annealed material exhibited higher dynamic loading and substantially larger burrs. The study confirms that smart toolholder-based vibration monitoring can provide useful information about changes in machining conditions during micro-milling of DMLS titanium alloy and can support further development of process diagnostics in finishing of biomedical components.

Keywords

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