Evaluation of Surface Roughness and Defect Formation after The Machining of Sintered Aluminum Alloy AlSi10Mg

Abstract

This article presents selected issues related to the workpiece surface quality after machining by the laser sintering of AlSi10MG alloy powder. The surfaces of the workpiece were prepared and machined by longitudinal turning with tools made of sintered carbides. The occurrence of breaches on the machined material surface was found, which negatively influence the values of 3D surface roughness parameters. The occurring phenomena were analyzed and proposals for their explanation were made. Guidelines for the machining of workpieces achieved by the laser sintering of powders were developed. The lowest value of the 3D roughness parameters was obtained for f = 0.06 mm/rev, ap = 0.5–1.0 mm, and for the nose radius of cutting insert rε = 0.8 mm. The results of research on the effect of cutting parameters on the values of parameters describing the surface quality are presented. Topography measurements and 3D surface roughness parameters are presented, as well as the results of a microscopic 3D surface analysis. Taguchi’s method was used in the research methodology.

Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

“…The analysis of down-milling and up-milling of sintered material and roughness, topography and microscopic measurements of the machined surface were carried out. The results presented in the paper are a continuation of the analyses undertaken by the authors as previously described [ 41 ].…”

Tribological Properties and 3D Topographic Parameters of Hard Turned and Ground Surfaces

“…Several studies have found that 3D surface topography parameters provide more exact information about the surface quality than the 2D parameters, e.g., [ 10 , 11 ] and this statement was recently confirmed by studies carried out typically for their comparison [ 12 , 13 ]. In the present study the topography measurements were carried out by optical equipment, whose reliability is higher than that of the conventional stylus solution [ 14 ].…”

Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

“…In this case, more favorable results were obtained for samples made by SLM. A similar set of samples (AlSi10Mg, casting / DMLS) was used by Struzikiewicz et al [22], who proved that in the case of orthogonal turning of laser sinters, products of lower surface finish are obtained. The problem was the appearance of burrs and chipping that adhered to the treated surface, reducing its quality.…”