Simulation of surface roughness evolution of additively manufactured material fabricated by laser powder bed fusion and post-processed by burnishing

Teimouri, Reza; Sohrabpoor, Hamed; Grabowski, Marcin; Wyszyński, Dominik; Skoczypiec, Sebastian; Raghavendra, Ramesh

doi:10.1016/j.jmapro.2022.09.045

Cited by 19 publications

(9 citation statements)

References 38 publications

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“…However, few studies have been conducted to enhance the internal surface texture of TC4 alloy embedded flow channels in lightweight space components via SLM. For open surfaces, the post-printing machining processes, such as milling and burnishing, can be used to enhance the dimensional accuracy and surface quality of SLM parts [ 43 , 44 ]. The conformal cooling channels [ 45 , 46 , 47 ] represent a valuable application of SLM as they are critical in reducing cooling times and residual stresses in molded plastic parts.…”

Section: Introductionmentioning

confidence: 99%

“…The higher surface roughness also influences parameters like friction factor and Nusselt number, with pronounced effects in channels with smaller hydraulic diameters [ 53 ]. The post-processing techniques, such as burnishing and abrasive flow machining (AFM), have been explored for their potential to refine these roughness disparities [ 43 , 54 , 55 ]. Notably, AFM shows promise in uniformly enhancing the surface quality, including both the top and bottom surfaces of internal channels [ 56 ].…”

Section: Introductionmentioning

confidence: 99%

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Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Islam,

Hao,

Javaid

et al. 2024

Micromachines

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A challenge remains in achieving adequate surface roughness of SLM fabricated interior channels, which is crucial for fuel delivery in the space industry. This study investigated the surface roughness of interior fine flow channels (1 mm diameter) embedded in SLM fabricated TC4 alloy space components. A machine learning approach identified layer thickness as a significant factor affecting interior channel surface roughness, with an importance score of 1.184, followed by scan speed and laser power with scores of 0.758 and 0.512, respectively. The roughness resulted from thin layer thickness of 20 µm, predominantly formed through powder adherence, while from thicker layer of 50 µm, the roughness was mainly due to the stair step effect. Slow scan speeds increased melt pools solidification time at roof overhangs, causing molten metal to sag under gravity. Higher laser power increased melt pools temperature and led to dross formation at roof overhangs. Smaller hatch spaces increased roughness due to overlapping of melt tracks, while larger hatch spaces reduced surface roughness but led to decreased part density. The surface roughness was recorded at 34 µm for roof areas and 26.15 µm for floor areas. These findings contribute to potential adoption of TC4 alloy components in the space industry.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Islam,

Hao,

Javaid

et al. 2024

Micromachines

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“…The previous studies show that the modeling approaches that meticulously consider the thermal transfer phenomena are limited in L-PBF structures with small dimensions and cannot be applied in realistic-sized parts due to their enormous computational cost. Promising analytical models proposed in the literature [25][26][27] offered valuable insights. These solutions utilized a coupled thermomechanical modeling approach, incorporating factors such as moving heat sources and scan strategies for thermal effects [25][26][27], as well as employing Green's functions to assess thermal stresses [25,26].…”

Section: Introductionmentioning

confidence: 99%

Efficient Simulation of the Laser-Based Powder Bed Fusion Process Demonstrated on Open Lattice Materials Fabrication

Psihoyos,

Lampeas

2024

Machines

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Strut-based or open lattice materials are a category of advanced materials used in medical and aerospace applications due to their properties, such as high strength-to-weight ratio and energy absorption capability. The most prominent method for the fabrication of lattice materials is the Laser-based Powder Bed Fusion (L-PBF) additive manufacturing (AM) process, due to its ability to produce parts of complex geometries. The current work presents an efficient meso-scale finite element (FE) modeling methodology of the L-PBF process demonstrated in the fabrication of body-centered cubic (BCC) lattice materials. The modeling efficiency is gained through an adaptive mesh refinement technique, which results in accurate and efficient prediction of the temperature field during the process evolution. To examine the efficiency of the modeling method, the computational time is compared with that of a conventional FE simulation, based on the element and birth technique. The temperature history difference between the two approaches is minor but the adaptive mesh modeling requires only a small portion of the simulation time of the conventional model. In addition, the computational results present a good correlation with the available experimental measurements for various process parameters validating the presented efficient method.

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“…To date, the research on the grinding process relates to both physical analysis of the process and determination of the correlation between the process parameters and the roughness and geometrical accuracy of the surface [ 28 ].…”

Section: Introductionmentioning

confidence: 99%

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625

et al. 2023

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Finishing operations are one of the most challenging tasks during a manufacturing process, and are responsible for achieving dimensional accuracy of the manufactured parts and the desired surface topography properties. One of the most advanced finishing technologies is grinding. However, typical grinding processes have limitations in the acquired surface topography properties, especially in finishing difficult to cut materials such as Inconel 625. To overcome this limitation, a new type of grinding wheel is proposed. The tool is made up of grains of different sizes, which results in less damage to the work surface and an enhancement in the manufacturing process. In this article, the results of an experimental study of the surface grinding process of Inconel 625 with single-granular and multi-granular wheels are presented. The influence of various input parameters on the roughness parameter (Sa) and surface topography was investigated. Statistical models of the grinding process were developed based on our research. Studies showed that with an increase in the cutting speed, the surface roughness values of the machined samples decreased (Sa = 0.9 μm for a Vc of 33 m/s for a multigranular wheel). Observation of the grinding process showed an unfavorable effect of a low grinding wheel speed on the machined surface. For both conventional and multigranular wheels, the highest value for the Sa parameter was obtained for Vc = 13 m/s. Regarding the surface topography, the observed surfaces did not show defects over large areas in the cases of both wheels. However, a smaller portion of single traces of active abrasive grains was observed in the case of the multi-granular wheel, indicating that this tool performs better finishing operations.

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Simulation of surface roughness evolution of additively manufactured material fabricated by laser powder bed fusion and post-processed by burnishing

Cited by 19 publications

References 38 publications

Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Efficient Simulation of the Laser-Based Powder Bed Fusion Process Demonstrated on Open Lattice Materials Fabrication

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625

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