On surface quality of engineered parts manufactured by additive manufacturing and postfinishing by machining

Pérez, Mercedes López; García-Collado, Alberto; Porto, Diego Carou; Sánchez, Giovanni; Dorado-Vicente, R.

doi:10.1016/b978-0-12-818411-0.00015-x

Cited by 5 publications

(3 citation statements)

References 75 publications

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“…In SLM, the fabrication of functionally complex part designs is enabled by the design and implementation of support structures which are defined as any material used to provide structural support to unsupported portions (e.g., overhangs, vertical holes, cantilevers, bridges) or critical features (e.g., thin wall features) of a printed part during the build process [6,7]. The use of supports is critical to produce high-quality metal parts in terms of dimensional, geometrical accuracy and structural integrity [8]. Miuri et al [9] demonstrated that the staircase effect and consequently the surface roughness of down-facing surfaces is reduced by support optimization, reducing curl formation which compromises the printing process by inducing local detrimental indentation of the recoater blade.…”

Section: Introductionmentioning

confidence: 99%

Influence of SLM block support design on geometrical quality of AISI 316 l cantilever features and its impact on post-processing

Pollicini,

Mazzucato,

Valente

2024

Mater. Res. Express

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In Selective Laser Melting, the design of efficient support structures is the key enabling the production of high-quality functional parts exhibiting complex shapes with improved geometrical accuracy. Nonetheless, from a process point of view, supports are waste material that must be minimized to reduce production costs and post-processing. Despite the recent technological advances, support optimization is based on time- and resource-consuming trial-and-error experimental campaigns, while support removal is primarily a manual operation which requires a consistent human effort and consumable consumption. Nowadays, the industry is demanding a tool capable to optimize support design and placement based on part geometry and building orientation, by ensuring high part geometrical accuracy along with reduced timing for post-processing operations. This research work is the starting point of a wide research activity aiming to design and develop a software tool for the automated engineering and implementation of optimized support structures based on both part and process requirements. Specifically, the influence of the support thickness and the tooth length on the final geometrical quality of AISI 316L cantilever features and on the post-processing phase (i.e., support removal) is analysed. The experimental results show that the support thickness strongly affects the final part distortion, reducing the as-built geometrical deviation by 72.6% when wall thickness increases up to 0.7 mm. On the contrary, tooth length reduces the post-processing time up to 40.5% and the usage of consumables up to 72.7% when decreased from 0.7 mm to 0.3 mm. The achieved results highlight that the implementation of optimized support structures ensuring low geometrical deviation and involving reduced resource consumption in post-processing is feasible. These findings provide the starting design rules for the engineering of an empirical methodology, based on thermomechanical modelling, enabling optimized design and implementation of SLM support structures.

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Section: Introductionmentioning

confidence: 99%

Influence of SLM block support design on geometrical quality of AISI 316 l cantilever features and its impact on post-processing

Pollicini,

Mazzucato,

Valente

2024

Mater. Res. Express

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“…It uses a layer-by-layer approach to manufacture complex geometries 2 and it works with a wide range of materials, such as plastics, metals, and ceramics. 3 There are several different technologies used in additive manufacturing. The ISO/ASTM 52900 standard classifies them into seven technologies.…”

Section: Introductionmentioning

confidence: 99%

“…8 Poor surface quality is one of the main drawbacks. Thus, the surface often requires postprocessing, 3 including chemical post-treatment and hot air jet, as demonstrated by Galantucci et al 9 and Adel et al, 10 respectively. However, postprocessing operations lead to higher manufacturing costs and time.…”

Section: Introductionmentioning

confidence: 99%

Examining the surface quality of inner and outer surfaces in material extrusion printed samples

Río

Carou

Pereira

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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This article presents an experimental study of the material extrusion process to examine the impact of less-analyzed factors on surface roughness, not including the commonly known layer height. The study also gives attention to the inner surfaces of printed samples. The design of experiments used a fractional factorial design with five two-level factors: bed temperature, fan percentage, printing speed, printing temperature, and wall thickness. Thus, the purpose of the design is screening. A two-dimensional contact profilometer was used to measure the surface roughness. Generally, the inner faces of the printed samples showed lower surface roughness. In addition, four analysis of variance showed that wall thickness (for Ra and Rz) and printing speed (for Ra) are significant for the outer and inner surfaces, respectively. As the wall thickness increased, the surface roughness decreased. Meanwhile, the lower the printing speed, the worse the surface quality on the inner faces.

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Experimental studies on fabricating functionally gradient material of stainless steel 316L-Inconel 718 through hybrid manufacturing: directed energy deposition and machining

Zhang

Nagaraja

Bian

et al. 2022

Int J Adv Manuf Technol

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On surface quality of engineered parts manufactured by additive manufacturing and postfinishing by machining

Cited by 5 publications

References 75 publications

Influence of SLM block support design on geometrical quality of AISI 316 l cantilever features and its impact on post-processing

Influence of SLM block support design on geometrical quality of AISI 316 l cantilever features and its impact on post-processing

Examining the surface quality of inner and outer surfaces in material extrusion printed samples

Experimental studies on fabricating functionally gradient material of stainless steel 316L-Inconel 718 through hybrid manufacturing: directed energy deposition and machining

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