Turn Milling of Inconel 718 Produced via Additive Manufacturing Using HVOF and DMLS Methods

Additive and coating technologies, such as high-velocity oxy-fuel (HVOF) thermal spraying and direct metal laser sintering (DMLS), often require extensive post-processing to meet dimensional and surface quality requirements, which remains challenging for nickel-based superalloys such as Inconel 718. This study presents the design and topology optimisation of a cutting tool with a linear cutting edge, capable of operating in turn-milling or turning modes, offering a viable alternative to conventional grinding. A non-optimised tool served as a baseline for comparison with a topology-optimised variant improving cutting-force distribution and stiffness-to-mass ratio. Finite element analyses and experimental turn-milling trials were performed on DMLS and HVOF Inconel 718 using carbide and CBN inserts. The optimised tool achieved significantly reduced roughness values: for DMLS, Ra decreased from 0.514 ± 0.069 µm to 0.351 ± 0.047 µm, and for HVOF from 0.606 ± 0.069 µm to 0.407 ± 0.069 µm. Rz was similarly improved, decreasing from 4.234 ± 0.343 µm to 3.340 ± 0.439 µm (DMLS) and from 5.349 ± 0.552 µm to 4.521 ± 0.650 µm (HVOF). The lowest measured Ra, 0.146 ± 0.030 µm, was obtained using CBN inserts at the highest tested cutting speed. All improvements were statistically significant (<i>p</i> < 0.005). No measurable tool wear was observed due to the small engagement and the use of a fresh cutting edge for each pass. The resulting surface quality was comparable to grinding and clearly superior to conventional turning. These findings demonstrate that combining topology optimisation with a linear-edge tool provides a practical and efficient finishing approach for additively manufactured and thermally sprayed Inconel 718 components.