Polyetheretherketone (PEEK) has good mechanical properties and biocompatibility for a wide range of biomedical applications. The combined 3D printing and milling process (CPMP) is a typical additive/subtractive hybrid manufacturing technique, which facilitates the rapid response for customized PEEK implants. This paper investigates the CPMP process combining fused deposition modeling printing and dry milling for PEEK materials. The results show that the bending and shearing effects of the milling cutter on the 3D-printed part cause the machined surface to be extremely susceptible to delamination. Poor Z-direction interlayer bonding strength at the 3D printing stage is the main cause of delamination. Therefore, the effects of 3D printing parameters (nozzle temperature, layer thickness, and bed temperature) on Z-direction interlayer bonding strength are studied using an orthogonal experiment design method. The applicability of three 3D printing infill patterns (grid, rectilinear, and gyroid) in CPMP is compared.The results of the research show that the storage modulus is a more accurate reflection of the interlayer bonding strength in the Z-direction than the shear strength. With a combination of parameters of a nozzle temperature of 450 C, a layer thickness of 0.1 mm, a bed temperature of 260 C and a rectilinear infill pattern, the 3D-printed parts have significantly stronger interlayer bonding strength.Consequently, there exists almost no delamination on the milled surface.
The application of polyetheretherketone (PEEK) in additive manufacturing (AM) can effectively reduce material and energy waste in the manufacturing process and help achieve lightweight parts. As a result, AM PEEK is considered an emerging technology in line with green manufacturing concepts. However, 3D-printed PEEK parts often suffer from low mechanical strength and poor surface quality due to the immaturity of the manufacturing process. Therefore, this research investigates the feasibility of improving the surface quality of 3D-printed parts by dry milling post-processing. Meanwhile, the mechanical strength of the parts is improved by optimizing the printing process parameters, and the effects of mechanical strength on milling quality are investigated. The novelty of this research is to design experiments based on the anisotropy of 3D-printed parts. For the first time, the delamination of the milling post-processing surface of 3D-printed PEEK parts is investigated. The results show that the milled surfaces of 3D-printed PEEK parts are prone to delamination problems. The printing direction has a significant effect on the quality of milling post-processing, whereas the milling directions have little effect on milling post-processing quality. The delamination problem can be significantly improved by a side milling process where the specimen is printed at 90° and then milled. Milling surface delamination is caused by the poor mechanical strength (internal bonding) of 3D-printed PEEK parts. By improving the mechanical strength of 3D-printed PEEK parts, the delamination of its milled surfaces can be significantly improved.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.
hi@scite.ai
10624 S. Eastern Ave., Ste. A-614
Henderson, NV 89052, USA
Copyright © 2024 scite LLC. All rights reserved.
Made with 💙 for researchers
Part of the Research Solutions Family.