A method to reduce smearing in the milling of metal foams

This research involves the investigation of process parameters for a new rapid machining process designed for metal foams. Metal foams are structures that contain a network of interconnected pores throughout the structure and surrounding surfaces. Traditional machining methods break down the pore walls of metal foams, creating a smeared surface finish with little to no surface porosity. The described research tasks include defining the significant process parameters for machining complex geometries of a metal foam, Trabecular MetalTM, commonly used in medical applications. It was found that feed rate significantly reduces the effect of surface smear, especially at faster rates. Machining with harder infiltrant materials and in a cryogenic environment will also better maintain surface porosity during machining. The impact of this research will allow for the creation of complex porous parts with a variety of applications including custom artificial bone