Post-Processing of Complex SLM Parts by Barrel Finishing

Boschetto, Alberto; Bottini, Luana; Macera, Luciano; Veniali, F.

doi:10.3390/app10041382

Cited by 47 publications

(20 citation statements)

References 25 publications

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“…Nalli et al [26] worked on the effect of process parameters of ACBF on dimensions and tensile behaviours of Ti-6Al-4 V parts. The results showed that the surface quality improved by increasing rotational speed while time was found as another important factor in this process by Boschato et al [27].…”

Section: Introductionmentioning

confidence: 84%

A comprehensive investigation of abrasive barrel finishing on hardness and manufacturability of laser-based powder bed fusion hollow components

Khorasani

Ghasemi

Farabi

et al. 2022

Int J Adv Manuf Technol

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One of the main issues of laser-based powder bed fusion (LB-PBF) parts is surface quality and dimensional deviations, which require post-processing. Conventional post-processing such as turning and milling cannot machine internal surfaces and therefore is not suitable for hollow components. In this paper, Ti–6Al–4 V components with different hollow shapes were printed by LB-PBF and post-processed by centrifugal barrel finishing (CBF). Samples were printed based on Taguchi L18 design of experiments (DoE) on the (L18: 21 × 33) matrix and polished in abrasive solution by porcelain triangular media 2 × 2 mm. The effect of process parameters including rotation direction, speed, time and volumetric percentage of abrasive on hardness and manufacturability, including surface quality, material removal rate (MRR) and dimensional deviation, are discussed. The novelty of this work is the application of this process to clean both the internal and external surfaces of LB-PBF parts, where previously it has only been investigated for external surfaces. This paper scrutinized the performance of the CBF on internal geometries, and it was shown for the size of the investigated components, the hexagonal hollow achieved the highest maximum removal rate over the square and circular hollows. In addition, the effect of CBF on plastic deformation and microstructural characterization has been investigated to find the effect of this process on work hardening. The results of this study also show that the rotational speed and the volumetric percentage of the abrasive directly drive the MRR. A higher rotational speed increases the slope of the sliding path and the sliding speed between printed parts and abrasive media, which causes higher cutting and grinding, MRR and media wear rate.

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Section: Introductionmentioning

confidence: 84%

A comprehensive investigation of abrasive barrel finishing on hardness and manufacturability of laser-based powder bed fusion hollow components

Khorasani

Ghasemi

Farabi

et al. 2022

Int J Adv Manuf Technol

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“…10e is obtained. It is well evident that no defect is present and only the usual SLM surface now characterizes the area [58,59].…”

Section: D Analysis For Surface Defects Detectionmentioning

confidence: 99%

Part defects identification in selective laser melting via digital image processing of powder bed anomalies

Boschetto

Bottini

Vatanparast

et al. 2022

Prod. Eng. Res. Devel.

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Despite the potential of additive manufacturing and specifically of selective laser melting, several considerable barriers exist to widespread utilization, especially in specific industries that produce high-value components. Quality control and mechanical characterization remain the most expensive challenge. The quality and mechanical properties of the manufactured parts are influenced by potential defects; the characteristics of these defects, such as size, shape, location, and distribution, have shown to play key roles in mechanical properties. This work proposes a methodology for providing the identification of powder bed anomalies and consequent part defects through a synchronized analysis of the powder layers via digital image processing. This method can be used to study the critical defects formation during the layerwise process, providing important information about their location without the use of expensive or destructive measurements.

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“…For example, to ensure a roughness of Ra < 1 µm, the process should run for at least 3 h [22]. The machining of additively manufactured components with complex geometry places especially high demands on the process, whereby the accessibility of the grinding particles to all areas should be ensured for homogeneous surface roughness [23,24]. This process can be used effectively in series production.…”

Section: Introductionmentioning

confidence: 99%

“…Each of these processes leads to a reduction in surface roughness due to its special material removal mechanism, which can be further increased by combining the described processes [2,13,24,39]. To investigate this effect, different finishing chains were realized.…”

mentioning

confidence: 99%

Efficient Finishing of Laser Beam Melting Additive Manufactured Parts

Henning

Aliyev

Gindorf

2021

JMMP

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In many cases, the functional performance of additively manufactured components can only be ensured by finishing the functional surfaces. Various methods are available for this purpose. This paper presents a procedure for selecting suitable processes for finishing laser beam melting additive–manufactured parts which is ultimately based on technological knowledge. It was experimentally proven that the use of several consecutive finishing processes is beneficial to achieve better surface quality. One finishing process chain was particularly effective (namely particle blasting/vibratory grinding/plasma electrolytic polishing) and the technological limits of this method were investigated in this study. The optimal parameters for this process combination ensured a surface roughness Sa < 1 µm.

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Post-Processing of Complex SLM Parts by Barrel Finishing

Cited by 47 publications

References 25 publications

A comprehensive investigation of abrasive barrel finishing on hardness and manufacturability of laser-based powder bed fusion hollow components

A comprehensive investigation of abrasive barrel finishing on hardness and manufacturability of laser-based powder bed fusion hollow components

Part defects identification in selective laser melting via digital image processing of powder bed anomalies

Efficient Finishing of Laser Beam Melting Additive Manufactured Parts

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