Development of a Workflow for Topological Optimization of Cutting Tool Milling Bodies Bruno Rafael Cunha, Bruno Miguel Guimarães, Daniel Figueiredo, Manuel Fernando Vieira, José Manuel Costa Metals, 2026 This study establishes a systematic and reproducible workflow for topology optimization (TO) of indexable face milling cutter bodies with integrated internal coolant channels, designed for Additive Manufacturing (AM) of metallic parts. Grounded in Design for Additive Manufacturing (DfAM) principles, the workflow combines displacement-based TO and computational fluid dynamics analysis to generate simulation-driven tool geometries tailored to the constraints of AM. By leveraging iterative design knowledge, the proposed methodology enhances the scalability and repeatability of the design process, reducing development time and supporting rapid adaptation across various tool geometries. AM is explicitly exploited to integrate support-free internal coolant channels directed toward the insert cutting edge, thereby achieving a 20% mass reduction relative to the initial milling tool designs, and improving material usage efficiency at the design stage. The workflow yields numerically optimized geometries that maintain simulated global stiffness under the considered loading conditions and exhibit coolant flow distributions that effectively target the exposed cutting edges. These simulation results demonstrate the feasibility of an AM oriented, workflow-based approach for the numerical design of milling tools with internal cooling, mass reduction and provide a focused basis for subsequent experimental validation and comparison with conventionally manufactured counterparts.
Robot Path Planning: from Analytical to Computer Intelligence Approaches Pedro A. Dias, João Pedro Carvalho de Souza, E. J. Solteiro Pires, Vítor Filipe, Daniel Figueiredo, et al. Journal of Intelligent and Robotic Systems Theory and Applications, 2025 In an era where robots are becoming an integral part of human quotidian activities, understanding how they function is crucial. Among the inherent building complexities, from electronics to mechanics, path planning emerges as a universal aspect of robotics. The primary contribution of this work is to provide an overview of the current state of robot path planning topics and a comparison between those same algorithms and its inherent characteristics. The path planning concept relies on the process by which an algorithm determines a collision-free path between a start and an end point, optimizing parameters such as energy consumption and distance. The quest for the most effective path planning method has been a long-standing discussion, as the choice of method is highly dependent on the specific application. This review consolidates and elucidates the categories of path planning methods, specifically classical or analytical methods, and computer intelligence methods. In addition, the operational principles of these categories will be explored, discussing their respective advantages and disadvantages, and reinforcing these discussions with relevant studies in the field. This work will focus on the most prevalent and recognized methods within the robotics path planning problem, being mobile robotics or manipulator arms, including Cell Decomposition, A*, Probabilistic Roadmaps, Rapidly-exploring Random Trees, Genetic Algorithms, Particle Swarm Optimization, Ant Colony Optimization, Artificial Potential Fields, Fuzzy, and Neural Networks. Following the detailed explanation of these methods, a comparative analysis of their advantages and drawbacks is organized in a comprehensive table. This comparison will be based on various quality metrics, such as the type of trajectory provided (global or local), the scenario implementation type (real or simulated scenarios), testing environments (static or dynamic), hybrid implementation possibilities, real-time implementation, completeness of the method, consideration of the robot’s kinodynamic constraints, use of smoothing techniques, and whether the implementation is online or offline.
Enhancing the cutting performance of laser surface textured WC–Co cutting tools—a study on AISI 316L stainless steel turning Bruno Guimarães, Francisco Marques, Cristina Fernandes, Daniel Figueiredo, Filipe Silva, et al. International Journal of Advanced Manufacturing Technology, 2025 During machining processes, cutting tools suffer severe tool wear, due to the friction generated at the tool-chip and tool-workpiece interfaces that produce a considerable amount of abrasion and heat in the cutting zone. Surface texturing has the ability to improve the cutting performance of cutting tools by providing enhanced lubricant availability to the inaccessible area of the tool-chip interface, increasing load carrying capacity, enhancing wetting properties and heat transfer coefficient and reducing the tool-chip contact area and chip on tool contact length, thus reducing friction, tool wear and cutting temperature and forces. This study presents a novel surface modification approach for fabricating cross-hatched micropatterns on the rake face of WC–Co cutting inserts, consisting in performing the laser surface texturing process in the green body of the inserts. The addition of micropatterns to WC–Co cutting tools decreased tool wear by 33%, when compared to a commercial cutting tool during turning of AISI 316L stainless steel, due to the improved ability to extract more heat in the cutting zone and nearer to the cutting edge, increased lubrication effect and reduced tool-chip contact area and length. Therefore, the findings obtained in this study are crucial for future developments of cutting tools with novel designs and features.
Optimising WC-25Co Feedstock and Parameters for Laser-Directed Energy Deposition Helder Nunes, José Nhanga, Luís Regueiras, Ana Reis, Manuel F. Vieira, et al. Journal of Manufacturing and Materials Processing, 2025 Laser-Directed Energy Deposition (L-DED) is an additive manufacturing technique used for producing and repairing components, mainly for coating applications, depositing metal matrix composites such as cemented carbides, composed of hard metal carbides and a metallic binder. In this sense, this study evaluated the preparation of a ready-to-press WC-25Co powder as a reliable feedstock for L-DED process. This powder required pre-heat treatment studies to prevent fragmentation during powder feeding, due to the absence of metallurgical bonding between WC and Co particles. In the current study, the Taguchi methodology was used, varying laser power, powder feed rate, and scanning speed to reach an optimised deposition window. The best bead morphology resulted from 2400 W laser power, 11 mm/s scanning speed, and 9 g/min feed rate. Moreover, defects such as porosity and cracking were mitigated by applying a remelting strategy of 2400 W and 9 mm/s. Therefore, a perfect deposition is obtained using the optimised processing parameters. Microstructural analysis of the optimised deposited line revealed a fine structure, comprising columnar and equiaxed dendrites of complex carbides. The average hardness of the deposited WC-25Co powder on a AISI 1045 steel was 854 ± 37 HV0.2. These results demonstrate the potential of L-DED for processing high-performance cemented carbide coatings.
WC-Co Versus Ticn/WC-Co, Ni For New Cutting Tools Gonçalo Oliveira, Ricardo Mineiro, Ana Maria Rocha Senos, Cristina Fernandes, Daniel Figueiredo, et al. Euro Powder Metallurgy 2023 Congress and Exhibition Pm 2023, 2023
Development of Low PcBN Composites by SPS Ricardo Mineiro, J. Rodrigues, C.M. Fernandes, D. Figueiredo, B. Ferrari, et al. Euro Powder Metallurgy 2023 Congress and Exhibition Pm 2023, 2023
Binder Jetting Of Hardmetals: A Comparative Study Of Microstructures And Properties Of Different Commercial Powders World Pm 2022 Congress Proceedings, 2022
Indirect Additive Manufacturing (Material Extrusion) as a Solution to a New Concept of Cutting Tools World Pm 2022 Congress Proceedings, 2022
Properties gradient in hardmetal parts achieved with recycled powders Euro Pm 2018 Congress and Exhibition, 2020
The Effect of Carbon Content on the Properties Gradient of Hardmetal Parts Attained with Recycled Powders Proceedings Euro Pm2020 Congress and Exhibition, 2020
Influence of Secondary Carbides on Ticn Based Cermets Compositions Proceedings Euro Pm2020 Congress and Exhibition, 2020
The effect of surface texturing on the temperature distribution on WC-Co cutting tools Proceedings Euro Pm2020 Congress and Exhibition, 2020
Chemical pretreatment optimization for improved diamond adhesion on hard metal substrates Proceedings Euro Pm2020 Congress and Exhibition, 2020
