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This paper presents a methodology for precision manufacture of a nozzle using the hybrid laser powder-bed fusion (L-PBF) technology. A new distortion predictive model for hybrid L-PBF was developed using finite element techniques. The model was validated against experimentally measured distortion using optical scanning. The validated model was utilised to mitigate distortion by applying additional stiffeners to the nozzle geometry where the distortion was reduced by 60% to acceptable tolerance of ± 200 µm. Micro-milling trials were conducted to identify optimum cutting parameters delivering high material removal rates while maintaining the average surface roughness of less than 1 µm. Finally, a nozzle with reduced distortion and desirable surface finish was manufactured, which has been used in industrial research context for process and product development of food products. [ABSTRACT FROM AUTHOR]

5-axis machining operations bring new challenges for predicting cutting forces. Complex tool workpiece engagements and tool orientations make it difficult to adapt 3-axis process models for 5-axis operations. A new model is developed to predict cutting forces with arbitrary tool/workpiece engagement and tool feed direction. A discretization approach is used, in which the tool is composed of multiple cutting elements. Each element is processed to determine its effect on cutting forces, and global forces are determined by combining the elemental effects. Cutting tests are conducted to verify force predictions, where the tool/workpiece engagement is provided through a geometric software application. [ABSTRACT FROM AUTHOR]