Numerical Modeling of Orthogonal Cutting in 3D-Printed PEEK: Process Parameters and Simulation Validation

Additive manufacturing (AM) is rapidly transforming industrial production by offering a low-waste and highly customizable alternative to traditional subtractive methods. However, tight dimensional tolerances and complex geometries often require post-process machining of 3D-printed components. Among high-performance thermoplastics, polyether-ether-ketone (PEEK) is preferred for its thermal stability and mechanical strength. A key novelty of this study addresses a critical gap in the literature: while some analyses of PEEK machining consider cutting and pressure parameters, few documented instances examine unreinforced PEEK at high cutting speeds. This knowledge gap is highly relevant because the absence of reinforcement and high cutting speeds interact through temperature-induced thermal softening. Utilizing a validated finite element model in ABAQUS, the research presents a comprehensive numerical investigation of the orthogonal micromachining of 3D-printed PEEK, analyzing the influence of printing parameters (building orientation and strategy) alongside machining variables (cutting speed and depth of cut). The study identifies critical anisotropic effects, where specific build orientations, particularly −45°, maximize mechanical resistance and heat generation. Conversely, multi-layer stacking sequences (e.g., 0°/90° and 45°/−45°) are shown to enhance structural rigidity and improve surface finish by optimizing chip formation mechanics and reducing interfacial temperatures. These findings provide a consistent framework for optimizing the post-processing of additively manufactured advanced polymers.