Longitudinal Milling and Fine Abrasive Finishing Operations to Improve Surface Integrity of Metal AM Components

Iquebal, Ashif Sikandar; Amri, Skander El; Shrestha, Sanjay; Wang, Zimo; Manogharan, Guhaprasanna; Bukkapatnam, Satish T. S.

doi:10.1016/j.promfg.2017.07.090

Cited by 37 publications

(14 citation statements)

References 8 publications

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“…Mechanical characterization with physical testing is also an important topic in the field of AM with different methods already considered as standards, to highlight García-Domínguez et al work where a full description and a comparative analysis of the existing standards are presented [12]. Another field of study is postprocessing, physical or chemical approaches which have been reported from sanding or milling [13] to different chemical baths [14].…”

Section: Introductionmentioning

confidence: 99%

Product Design by Additive Manufacturing for Water Environments: Study of Degradation and Absorption Behavior of PLA and PETG

et al. 2021

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Additive manufacturing technologies are shifting from rapid prototyping technologies to end use or final parts production. Polymeric material extrusion processes have been broadly addressed with a specific definition of all parameters and variables for all different of technologies approaches and materials. Recycled polymeric materials have been studied due to the growing importance of the environmental awareness of the contemporary society. Beside this, little specific research has been found in product development applications for AM where the printed parts are in highly moisture environments or surrounded by water, but polymers have been for long used in such industries with conventional manufacturing approaches. This work focuses on the analysis and comparison of two different additively manufactured polymers printed by fused filament fabrication (FFF) processes using desktop-size printers to be applied for product design. The polymers used have been a recycled material: polyethylene terephthalate glycol (PETG) and polylactic acid (PLA). Degradation and water absorption behaviors of both materials are presented, analyzed and discussed in this paper, where different samples have been immersed in saturated solutions of water with maritime salt and sugar together with a control sample immersed in distilled water. The samples have been dimensionally and weight-controlled weekly as well as microscopically analyzed to understand degradation and absorption processes that appear in the fully saturated solutions. The results revealed how the absorption process is stabilized after a reduced number of weeks for both materials and how the degradation process is more remarked in the PLA material due to its organic nature.

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Section: Introductionmentioning

confidence: 99%

Product Design by Additive Manufacturing for Water Environments: Study of Degradation and Absorption Behavior of PLA and PETG

et al. 2021

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“…Additionally, support structures on overhanging surfaces have to be mechanically removed from the part. Subtractive machining processes with a defined cutting edge are used in particular for post-processing [14,15]. This is currently done based on experiences gathered from decades of conventional, subtractive manufacturing methods [15][16][17].…”

Section: Introductionmentioning

confidence: 99%

“…Subtractive machining processes with a defined cutting edge are used in particular for post-processing [14,15]. This is currently done based on experiences gathered from decades of conventional, subtractive manufacturing methods [15][16][17]. Additively produced parts are mostly treated as raw feedstock with complex geometries, although the additive process can be used for more complex considerations in order to adapt and improve the overall efficiency of the process chain and the manufactured parts themselves.…”

Section: Introductionmentioning

confidence: 99%

Improving machinability of additively manufactured components with selectively weakened material

Maucher

Teich

Möhring

2021

Prod. Eng. Res. Devel.

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Part design and the possibilities of production are disrupted by the increased usage of additive manufacturing (AM). Featuring excellent creative freedom due to the layer-by-layer buildup of components, AM leads to profound changes in future part design and enables previously impossible geometries. Laser powder bed fusion (LPBF) technology already allows to manufacture small quantities of parts with high productivity and material efficiency. Due to the specific process characteristics, the resulting surface finish of these parts is insufficient for a wide range of applications, and post-processing is usually unavoidable. Specifically for functional surfaces, this post-processing is often done by machining processes, which can pose challenges for intricate and complex AM parts due to excessive machining forces. In the present paper, the influence and the possibilities of the LPBF process parameters on the subtractive post-processing are shown. A novel weakened structure is developed to selectively reduce the strength of the material and improve the cutting conditions. Chip formation, cutting forces and vibrations during drilling as well as cutting forces during an orthogonal cut are examined. To quantify the differences, a comparison of the machinability between bulk material, standard support structures and the weakened structure is carried out.

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“…It was concluded that the flood cooling resulted in minimal tool wear. In [ 33 ], an integrated post-processing strategy combining longitudinal milling with fine abrasive finishing is presented to enhance 3D printed parts’ surface integrity. This strategy could produce a surface finish up to 25 nm and decrease the surface porosity by 89%.…”

Section: Introductionmentioning

confidence: 99%

Optimizing 3D Printed Metallic Object’s Postprocessing: A Case of Gamma-TiAl Alloys

2021

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Gamma-TiAl (γ-TiAl) alloys can be used in high-end products relevant to the aerospace, defense, biomedical, and marine industries. Fabricating objects made of γ-TiAl alloys needs an additive manufacturing process called Electron Beam Melting (EBM) or other similar processes because these alloys are difficult-to-cut materials. An object fabricated by EBM exhibits poor surface finish and must undergo postprocessing. In this study, cylindrical specimens were fabricated by EBM and post-processed by turning at different cutting conditions (cutting speed, depth of cut, feed rate, insert radius, and coolant flowrate). The EBM conditions were as follows: average powder size 110 μm, acceleration voltage 60 kV, beam current 10 mA, beam scanning speed 2200 mm/s, and beam focus offset 0.20 mm. The surface roughness and cutting force were recorded for each set of cutting conditions. The values of the cutting conditions were set by the L36 Design of Experiment approach. The effects of the cutting conditions on surface roughness and cutting force are elucidated by constructing the possibility distributions (triangular fuzzy numbers) from the experimental data. Finally, the optimal cutting conditions to improve the surface finish of specimens made of γ-TiAl alloys are determined using the possibility distributions. Thus, this study’s outcomes can be used to develop intelligent systems for optimizing additive manufacturing processes.

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Longitudinal Milling and Fine Abrasive Finishing Operations to Improve Surface Integrity of Metal AM Components

Cited by 37 publications

References 8 publications

Product Design by Additive Manufacturing for Water Environments: Study of Degradation and Absorption Behavior of PLA and PETG

Product Design by Additive Manufacturing for Water Environments: Study of Degradation and Absorption Behavior of PLA and PETG

Improving machinability of additively manufactured components with selectively weakened material

Optimizing 3D Printed Metallic Object’s Postprocessing: A Case of Gamma-TiAl Alloys

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