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Additive manufacturing, particularly in the realm of rapid tool manufacturing, has seen exponential growth owing to its ability to produce mass-customized tools. This study focuses on the development of a copper tool using Metal Fused Filament Fabrication method and assess its performance in comparison with a conventional tool when machiningInconel 625. A mixed-level Taguchi L18 orthogonal array was selected for experimentation with varying process parameters including tool material, pulse-on, pulse-off duration and current (I). Results showed improved surface roughness and overcut with the AM tool, whilethe conventional tool had 7% higher material removal rate SEM morphological study compares surface finish and tool failure performance. This work provides insights into the durability and longevity of the AM tool compared with its conventional counterpart. The importance of parameter optimization for AM tools is also emphasized. These findings complement to the growing body of evidence for the adoption of additive manufacturing for applications that require customization, precision and rapid manufacturing.
Murali et al. (Thu,) studied this question.