Experimental study on finishing of internal laser melting (SLM) surface with abrasive flow machining (AFM)

Duval-Chaneac, M.S.; Han, Sangil; Claudin, C.; Salvatore, Ferdinando; Bajolet, Julien; Rech, J.

doi:10.1016/j.precisioneng.2018.03.006

Cited by 61 publications

(26 citation statements)

References 9 publications

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“…Chaneac et. al [24] used laser melting mechanism for the finishing of non heat treated maraginig steel 300 and observed that media viscosity and abrasive concentration affected the areal roughness. Bremerstein et.…”

Section: Orbital Afmmentioning

confidence: 99%

Various developments in Abrasive Flow Machining Process: A Review

Ali

Walia

et al. 2019

IJAPIE

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Abrasive flow machining is a nonconventional process used for polishing of metallic components, internal inaccessible cavities or recesses using a semi liquid paste. It was developed to deburr, polish the surfaces having complex geometries and edges by flowing abrasive particles with a visco-elastic nonconductive media over them. Abrasive particle sharp cutting edges remove the material by abrasion mechanism from the workpiece surface. In the recent year, work has been carryout towards the development of abrasive flow machining for achieving the higher material removal and improved surface finish. This method has a unique property of simultaneous improvement in material removal and surface finish. In this paper authors discussed about various recent developments in abrasive flow machining with major objective of improving the productivity of the process.

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Section: Orbital Afmmentioning

confidence: 99%

Various developments in Abrasive Flow Machining Process: A Review

Ali

Walia

et al. 2019

IJAPIE

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“…Moreover, the melt depth is larger than the layer thickness (since previous layers are also remelted to ensure sufficient bonding between the built layers [Yadroitsev et al 2013;Kamath et al 2014]), which induces a shape deviation (such as dross [Charles et al 2020;Feng et al 2020]) since the solidified thickness is larger than the designed one. In the microscale, printed surfaces (R a and S a ∼ 10 μm) are rougher than mechanically machined surfaces (Duval-Chaneac et al 2018;Wen et al 2018). This problem is especially severe for overhang regions whose surface roughness (R a ) is usually around 20 μm as a result of unmelted powder adhering to the edges of the solidified melt pool (Mazur et al 2016;Pakkanen et al 2016).…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical investigation of the origin of surface roughness in laser powder bed fused overhang regions

Feng

Kamat

Sabooni

et al. 2021

Virtual and Physical Prototyping

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Surface roughness of laser powder bed fusion (L-PBF) printed overhang regions is a major contributor to deteriorated shape accuracy/surface quality. This study investigates the mechanisms behind the evolution of surface roughness (R a) in overhang regions. The evolution of surface morphology is the result of a combination of border track contour, powder adhesion, warp deformation, and dross formation, which is strongly related to the overhang angle (θ). When 0°≤ θ ≤ 15°, the overhang angle does not affect R a significantly since only a small area of the melt pool boundaries contacts the powder bed resulting in slight powder adhesion. When 15°< θ ≤ 50°, powder adhesion is enhanced by the melt pool sinking and the increased contact area between the melt pool boundary and powder bed. When θ > 50°, large waviness of the overhang contour, adhesion of powder clusters, severe warp deformation and dross formation increase R a sharply.

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“…Many methods have been proposed for finishing the internal faces of tubes and channels. Duval-Chaneac et al [13] performed abrasive flow machining (AFM) on non-heattreated and heat-treated maraging steel 300 SLM surfaces with four different media under various abrasive concentrations (35%, 50%, and 65%) and different media viscosities (low viscosity and medium viscosity). The results indicated that abrasive concentration and media viscosity affect the evolution of areal roughness (Sa) in AFM for both non-heat-treated and heat-treated surfaces.…”

Section: Introductionmentioning

confidence: 99%

Internal face finishing for a cooling channel using a fluid containing free abrasive grains

Yamaguchi

Furumoto

Inagaki

et al. 2021

Int J Adv Manuf Technol

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In die-casting and injection molding, a conformal cooling channel is applied inside the dies and molds to reduce the cycle time. When the internal face of the channel is rough, both cooling performance and tool life are negatively affected. Many methods for finishing the internal face of such channels have been proposed. However, the effects of the channel diameter on the flow of a low-viscosity finishing media and its finishing characteristics for H13 steel have not yet been reported in the literature. This study addresses these deficiencies through the following: the fluid flow in a channel was computationally simulated; the flow behavior of abrasive grains was observed using a high-speed camera; and the internal face of the channel was finished using the flow of a fluid containing abrasive grains. The flow velocity of the fluid with the abrasive grains increases as the channel diameter decreases, and the velocity gradient is low throughout the channel. This enables reduction in the surface roughness for a short period and ensures uniform finishing in the central region of the channel; however, over polishing occurs owing to the centrifugal force generated in the entrance region, which causes the form accuracy of the channel to partially deteriorate. The outcomes of this study demonstrate that the observational finding for the finishing process is consistent with the flow simulation results. The flow simulation can be instrumental in designing channel diameters and internal pressures to ensure efficient and uniform finishing for such channels.

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Experimental study on finishing of internal laser melting (SLM) surface with abrasive flow machining (AFM)

Cited by 61 publications

References 9 publications

Various developments in Abrasive Flow Machining Process: A Review

Various developments in Abrasive Flow Machining Process: A Review

Experimental and numerical investigation of the origin of surface roughness in laser powder bed fused overhang regions

Internal face finishing for a cooling channel using a fluid containing free abrasive grains

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