Physics-Informed Machining

This DEVCOM ARL funded research sits at the intersection of advanced manufacturing and machining science, with a focus on the practical application of milling dynamics and tool path strategies within hybrid manufacturing environments. This work spans several cutting-edge additive processes — including Laser Powder Bed Fusion, Additive Friction Stir Deposition, and Cold Spray Additive Manufacturing — each presenting unique material characteristics that challenge conventional machining assumptions. Central to this research is a comparative analysis of milling forces between additively manufactured components and traditional billet or stock materials. Through hands-on prototype development, researchers investigate how microstructural differences, surface roughness variation, and residual thermal effects introduced during the additive process influence machinability, tool wear, and surface integrity — bridging the gap between emerging fabrication technologies and the precision demands of real-world production and cutting-edge research.