THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING

Çevik, Zihni Alp; Özsoy, Koray; Erçetin, Ali

doi:10.46519/ij3dptdi.947650

Cited by 9 publications

(6 citation statements)

References 21 publications

(16 reference statements)

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“…Additive manufacturing (AM) is a process that has entered our lives due to the insufficiency of old methods; it enables the computer-aided design of a three-dimensional model to be presented as a product [1][2][3]. In the AM procedure, a three-dimensional model is created utilizing the model data due to the material being deposited layer by layer [4].…”

Section: Introductionmentioning

confidence: 99%

Dimensional accuracy of acrylonitrile butadiene styrene and polylactic acid samples printed in vacuum-assisted material extrusion system

Shahrum,

Rajendran,

Maidin

et al. 2024

Eng. Res. Express

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This paper discusses the impact of integrating a vacuum system into a material extrusion 3D printing process for acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) materials. The study aimed to investigate the effect of a vacuum system on the dimensional accuracy of the printed samples. The vacuum system improved material flow and reduced dimensional deviations by reducing air molecules and minimizing convection. The results indicated a significant enhancement in dimensional accuracy for both ABS and PLA samples when using the vacuum system. ABS samples showed a 4% increase in accuracy, while PLA samples exhibited a 2% improvement compared to samples printed without vacuum assistance. These improvements were achieved by optimizing process parameters such as layer height (0.15 mm), infill percentage (10%), printing speed (45 mm/s), and bed temperature (60°C). These parameters were selected to ensure finer details, improved precision, structural support, stability, better adhesion, and reduced warping.

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Section: Introductionmentioning

confidence: 99%

Dimensional accuracy of acrylonitrile butadiene styrene and polylactic acid samples printed in vacuum-assisted material extrusion system

Shahrum,

Rajendran,

Maidin

et al. 2024

Eng. Res. Express

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“…The Selective Laser Melting (SLM) method belongs to the powder bed fusion (PBF) class, where metallic powder layers are solidified based on pre-generated g-codes using a slicing program until the desired part is fully fabricated [ 13 , 14 , 15 ]. SLM offers a high degree of flexibility in producing metallic parts with intricate shapes and geometries [ 16 , 17 ].…”

Section: Introductionmentioning

confidence: 99%

Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64

et al. 2023

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Selective laser melting (SLM) is a three-dimensional (3D) printing process that can manufacture functional parts with complex geometries as an alternative to using traditional processes, such as machining wrought metal. If precision and a high surface finish are required, particularly for creating miniature channels or geometries smaller than 1 mm, the fabricated parts can be further machined. Therefore, micro milling plays a significant role in the production of such miniscule geometries. This experimental study compares the micro machinability of Ti-6Al-4V (Ti64) parts produced via SLM compared with wrought Ti64. The aim is to investigate the effect of micro milling parameters on the resulting cutting forces (Fx, Fy, and Fz), surface roughness (Ra and Rz), and burr width. In the study, a wide range of feed rates was considered to determine the minimum chip thickness. Additionally, the effects of the depth of cut and spindle speed were observed by taking into account four different parameters. The manufacturing method for the Ti64 alloy does not affect the minimum chip thickness (MCT) and the MCT for both the SLM and wrought is 1 μm/tooth. SLM parts exhibit acicular α martensitic grains, which result in higher hardness and tensile strength. This phenomenon prolongs the transition zone of micro-milling for the formation of minimum chip thickness. Additionally, the average cutting force values for SLM and wrought Ti64 fluctuated between 0.072 N and 1.96 N, depending on the micro milling parameters used. Finally, it is worth noting that micro-milled SLM workpieces exhibit lower areal surface roughness than wrought ones.

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“…In addition, they observed adhered material on the tool edges as opposed to abrasion wear and no microstructural changes. Çevik et al [15] enhanced the surface quality of samples made from Ti6Al4V alloy using powder bed-fed additive manufacturing with various processing parameters by applying an additional process, such as CNC machining. The Ti6Al4V samples exhibited greater machinability with lower cutting forces and lower surface roughness due to the material's rapid cooling.…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization of Additively Manufactured Ti6Al4V Component Using Grey Relational Analysis Coupled with Entropy Weights

Alqahtani

Dabwan

Abualsauod

et al. 2023

Metals

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Due to its near-net-shape manufacturing and ability to treat challenging-to-manufacture materials such as titanium alloys, Additive manufacturing (AM) is growing in popularity. However, due to the poor surface quality of AM components, finishing processes such as machining are required. One of the most difficult aspects of finishing AM components is the fact that even when using the same machining parameters, the surface roughness can vary significantly depending on the orientation of the part. In this study, electron beam melting (EBM) Ti6Al4V parts are subjected to the finishing (milling) process in three potential orientations relative to the direction of the tool feed. The impact of the feed rate, radial depth of cut, and cutting speed on the surface roughness and cutting force of the Ti6Al4V EBM part is studied while taking the orientations of the EBM components into consideration. It is found that the machined surface changes in noticeable ways with respect to orientation. A factorial design is used for the experiments, and analysis of variance (ANOVA) is used to evaluate the results. Furthermore, the grey relational analysis (GRA) method coupled with entropy weights is utilized to determine the optimal process variables for machining a Ti6Al4V EBM component. The results show that the feed rate has the greatest impact on the multi-response optimization, followed by the cutting speed, faces, and radial depth of cut.

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THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING

Cited by 9 publications

References 21 publications

Dimensional accuracy of acrylonitrile butadiene styrene and polylactic acid samples printed in vacuum-assisted material extrusion system

Dimensional accuracy of acrylonitrile butadiene styrene and polylactic acid samples printed in vacuum-assisted material extrusion system

Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64

Multi-Response Optimization of Additively Manufactured Ti6Al4V Component Using Grey Relational Analysis Coupled with Entropy Weights

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