The student Mikel Etxebeste Gallardo obtained an EXCELLENT CUM LAUDE with mention INTERNATIONAL DOCTORATE

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The student Mikel Etxebeste Gallardo obtained an EXCELLENT CUM LAUDE with mention INTERNATIONAL DOCTORATE

THESIS

The student Mikel Etxebeste Gallardo obtained an EXCELLENT CUM LAUDE with mention INTERNATIONAL DOCTORATE

2026·04·27

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  • Thesis title: Virtual Optimization of Cutting Tools using Multiscale FEM, Integrated Methods, and Additive Manufacturing for Improved Machining Dynamics

Court:

  • Presidency: Ana María Camacho López (UNED)
  • Vocal: Philipp Imgrund (Fraunhofer IAPT)
  • Vocal: Ana Isabel Fernández Abia (Universidad de León)
  • Vocal: Patxi Aristimuño Osoro (Mondragon Unibertsitatea)
  • Secretary: Gorka Ortiz de Zarate Bengoa (Mondragon Unibertsitatea)

Abstract:

Machining is often constrained by dynamics-related issues, particularly chatter vibrations. Cutting tool design strongly affects productivity and stability, yet conventional trial-and-error approaches are costly and inefficient. This thesis presents a virtual optimization framework using multiscale FEM, combining meso-scale force prediction with macro-scale structural and dynamic analyses. Topology Optimization (TO) and Tuned Mass Dampers (TMDs) are integrated to improve dynamic performance, while Additive Manufacturing (AM) enables fabrication of highly optimized and complex geometries. Four industrial case studies, including milling and turning tools, validated the methodology through modal analysis and machining tests. The framework effectively bridges scientific modeling and industrial application, supporting the development of high-performance cutting tools.