Additively manufactured (AM) components possess microstructures different from conventional forms in the same material and as a consequence, the mechanical properties and machinability of components produced using these technologies differ. Also, the microstructures from these processes are often anisotropic and as such different regions possess varying properties and hence varying response during post process machining. An adaptive control (AC) machining system for addressing this variation in microstructures during post process machining is developed here and its use demonstrated in this paper.

The adaptive control system is used in milling and drilling trials for machining components manufactured by Directed Energy Deposition (DED). Surface roughness and residual stress analysis in the ‘as built’ state and after post process machining with the prevailing cutting forces are also presented here. Microstructures of the deposited material and the subsurface effects at the machined region due to the action of the cutting tool is also analysed.

Milling trials are investigated from the standpoint of the use of adaptive machining for the removal of the outermost layer of DED produced Ti6Al4V and in the machining of bulk regions after preliminary machining of the undulating layer. Drilling experiments are carried out for investigating the effects of the machining process on the resulting surface condition, comparing the process with and without adaptive control. The effects of variation in cutting forces during drilling through the different material systems comprising of the DED region and the wrought substrate is also discussed. The effect of periodic changes in cutting forces during machining due to the variation in microstructure along the build direction is analysed and discussed. The use of adaptive control machining for post processing is shown to improve surface finish as it reduces the initiation and generation of chatter marks on the machined surface resulting from material anisotropicity.

增材制造（AM）组件在相同的材料中具有不同于常规形式的微观结构，因此，使用这些技术生产的组件的机械性能和可加工性不同。而且，来自这些过程的微结构通常是各向异性的，因此，不同的区域具有变化的特性，因此在后处理加工期间具有变化的响应。本文开发了一种自适应控制（AC）加工系统，用于解决后加工过程中微结构的这种变化，并在本文中进行了演示。

自适应控制系统用于铣削和钻孔试验中，以加工由定向能量沉积（DED）制造的零件。此处还介绍了处于“已建好”状态以及采用主流切削力进行后加工后的表面粗糙度和残余应力分析。还分析了沉积材料的微观结构以及由于切削工具的作用而在加工区域产生的次表面效应。

从使用自适应加工去除DED生产的Ti6Al4V的最外层的角度研究了铣削试验以及在对波状层进行初步加工之后的大块区域加工中。进行钻孔实验以调查加工过程对所得表面条件的影响，比较采用和不采用自适应控制的过程。还讨论了在钻通包括DED区域和锻造基材的不同材料系统时切削力变化的影响。分析和讨论了切削过程中切削力周期性变化的影响，这种变化是由于微观组织沿加工方向的变化而引起的。自适应控制加工用于后期处理显示出改善的表面光洁度，因为它减少了由于材料各向异性而导致的加工表面颤动痕迹的产生和产生。