ANISOTROPIC CUTTING FORCE CHARACTERISTICS IN MILLING OF MARAGING STEEL PROCESSED THROUGH SELECTIVE LASER MELTING

2021 ◽  
pp. 1-16
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura ◽  
Atsushi Ezura ◽  
Kazuo Mori
Keyword(s):  
Additive Manufacturing ◽  
Cutting Force ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cutting Forces ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Force Model ◽  
Laser Melting ◽  
Scanning Direction

Abstract Additive manufacturing process of maraging steel has been studied for high value parts in aerospace and automotive industries. The hybrid additive / subtractive manufacturing is effective to achieve tight tolerances and surface finishes. The additive process induces anisotropic mechanical properties of maraging steel, which depends on the laser scanning direction. Because anisotropy in the workpiece material has an influence on the cutting process, the surface finish and the dimension accuracy change according to the direction of the cutter feed with respect to the laser scanning direction. Therefore, the cutting parameters should be determined to control the cutting force considering material anisotropy. The paper discusses the cutting force in milling of maraging steel stacked with selective laser melting, as an additive manufacturing process. Anisotropic effect on the cutting forces is proved with the changing rate of the cutting force in milling of the workpieces stacked by repeating laser scanning at 0/90 degrees and 45/-45 degrees. The cutting forces, then, are analyzed in the chip flow models with piling up of orthogonal cuttings. The force model associates anisotropy with the shear stress on the shear plane. The changes in the cutting forces with the feed direction are discussed in the cutting tests and analysis.

Anisotropic Cutting Force Characteristics in Milling of Maraging Steel Processed Through Selective Laser Melting

2021 ◽  
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura ◽  
Atsushi Ezura ◽  
Kazuo Mori
Keyword(s):  
Additive Manufacturing ◽  
Cutting Force ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cutting Forces ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Force Model ◽  
Laser Melting ◽  
Scanning Direction

Abstract Additive manufacturing process of maraging steel has been studied for high value parts in aerospace and automotive industries. The hybrid additive / subtractive manufacturing is effective to achieve tight tolerances and surface finishes. The additive process induces anisotropic mechanical properties of maraging steel, which depends on the laser scanning direction. Because anisotropy in the workpiece material has an influence on the cutting process, the surface finish and the dimension accuracy change according to the direction of the cutter feed with respect to the laser scanning direction. Therefore, the cutting parameters should be determined to control the cutting force considering material anisotropy. The paper discusses the cutting force in milling of maraging steel stacked with selective laser melting, as an additive manufacturing process. Anisotropic effect on the cutting forces is proved with the changing rate of the cutting force in milling of the workpieces stacked by repeating laser scanning at 0/90 degrees and 45/−45 degrees. The cutting forces, then, are analyzed in the chip flow models with piling up of orthogonal cuttings. The force model associates anisotropy with the shear stress on the shear plane. The changes in the cutting forces with the feed direction are discussed in the cutting tests and analysis.

scholarly journals Additive manufacturing of WC reinforced maraging steel 300 composites by cold spraying and selective laser melting

2019 ◽  
Vol 371 ◽  
pp. 161-171 ◽  
Author(s):  
Xingchen Yan ◽  
Chunjie Huang ◽  
Chaoyue Chen ◽  
Rodolphe Bolot ◽  
Lucas Dembinski ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cold Spraying ◽  
Laser Melting

scholarly journals In situ monitoring methods for selective laser melting additive manufacturing process based on images — A review

China Foundry ◽  
2021 ◽  
Vol 18 (4) ◽  
pp. 265-285
Author(s):  
Bo Wu ◽  
Xiao-yuan Ji ◽  
Jian-xin Zhou ◽  
Huan-qing Yang ◽  
Dong-jian Peng ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Manufacturing Process ◽  
In Situ Monitoring ◽  
Monitoring Methods ◽  
Laser Melting

scholarly journals Feedback Control of Melt Pool Area in Selective Laser Melting Additive Manufacturing Process

Processes ◽  
2021 ◽  
Vol 9 (9) ◽  
pp. 1547
Author(s):  
Syed Zahid Hussain ◽  
Zareena Kausar ◽  
Zafar Ullah Koreshi ◽  
Shakil R. Sheikh ◽  
Hafiz Zia Ur Rehman ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Feedback Control ◽  
Selective Laser Melting ◽  
Manufacturing Process ◽  
Thermal Model ◽  
Laser Melting ◽  
Powder Bed ◽  
Melt Pool ◽  
Melt Pool Size ◽  
Pool Area

Selective laser melting (SLM), a metal powder fusion additive manufacturing process, has the potential to manufacture complex components for aerospace and biomedical implants. Large-scale adaptation of these technologies is hampered due to the presence of defects such as porosity and part distortion. Nonuniform melt pool size is a major cause of these defects. The melt pool size changes due to heat from the previous powder bed tracks. In this work, the effect of heat sourced from neighbouring tracks was modelled and feedback control was designed. The objective of control is to regulate the melt pool cross-sectional area rejecting the effect of heat from neighbouring tracks within a layer of the powder bed. The SLM process’s thermal model was developed using the energy balance of lumped melt pool volume. The disturbing heat from neighbouring tracks was modelled as the initial temperature of the melt pool. Combining the thermal model with disturbance model resulted in a nonlinear model describing melt pool evolution. The PID, a classical feedback control approach, was used to minimize the effect of intertrack disturbance on the melt pool area. The controller was tuned for the desired melt pool area in a known environment. Simulation results revealed that the proposed controller regulated the desired melt pool area during the scan of multiple tracks of a powder layer within 16 milliseconds and within a length of 0.04 mm reducing laser power by 10% approximately in five tracks. This reduced the chance of pore formation. Hence, it enhances the quality of components manufactured using the SLM process, reducing defects.

scholarly journals Uncertainty assessment for measurement and simulation in selective laser melting: a case study of an aerospace part

ACTA IMEKO ◽  
2020 ◽  
Vol 9 (4) ◽  
pp. 96
Author(s):  
Giulio D'Emilia ◽  
Antoniomaria Di Ilio ◽  
Antonella Gaspari ◽  
Emanuela Natale ◽  
Antonios G. Stamopoulos
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Manufacturing Process ◽  
Thermal Stresses ◽  
Hybrid Approach ◽  
Coordinate Measuring Machine ◽  
Thermal Treatments ◽  
Laser Melting ◽  
Measuring Machine ◽  
Simulation Results

<p class="Abstract"><span lang="EN-US">In this work, the additive manufacturing process selective laser melting is analysed with the aim of realising a complex piece for aerospace applications. In particular, the effect of the manufacturing process and of the following thermal treatments on the dimensions of the workpiece is evaluated. The study is based on a hybrid approach including a simulation of the whole manufacturing process by advanced software packages and the dimensional measurements of the realised pieces taken by a coordinate measuring machine (CMM). The integrated use of simulation and measurements is carried out with the aim of validating the simulation results and of identifying the operational limits of both approaches; this analysis is based on metrological evaluation of the results of both the simulation and the tests, taking into account the uncertainty of the data. In addition, the main causes of uncertainty for the simulation activity and the experimental data have been identified, and the effects of some of them have also been experimentally evaluated. Based on the experimental validation, the simulation seems to predict the absolute displacement of the supports of the piece in a satisfactory way, while it is unable, in the actual configuration, to assess the conformity of the surface to its very tight shape tolerances. Conformity assessment of the surface should be carried out by CMM measurement. Integrated use of simulation and experimental results is expected to strongly improve the accuracy of simulation results for the effective and accurate design and control of the additive manufacturing process, including dimensional control and thermal treatments to mitigate induced thermal stresses.</span></p>

Oberflächengüte additiv gefertigter Kupferbauteile*/Surface quality of additive copper alloy parts – Investigations to increase the surface quality of top and side faces of SLM-generated CuCr1Zr copper alloy parts

2018 ◽  
Vol 108 (11-12) ◽  
pp. 815-820
Author(s):  
E. Uhlmann ◽  
V. Kashevko
Keyword(s):  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Manufacturing Process ◽  
Copper Alloy ◽  
Geometric Complexity ◽  
Laser Melting

Das Laserstrahlschmelzen (SLM) als additives Fertigungsverfahren ist prädestiniert für die Herstellung von individuellen Bauteilen oder Werkzeugen mit hoher geometrischer Komplexität durch äußere und innenliegende Features in der Einzelstück- und Kleinserienfertigung. Allerdings ist die Oberflächengüte sowohl der Deck- als auch Seitenflächen von SLM-generierten Bauteilen nach dem Fertigungsprozess noch nicht zufriedenstellend, was für die Anwendung, etwa als Werkzeugeinsatz, von immenser Bedeutung ist. Daher ist die Verbesserung der Oberflächenbeschaffenheit von Kupferbauteilen der Schwerpunkt dieser Untersuchung. &nbsp; Selective Laser Melting (SLM) as an additive manufacturing process is well suited for the production of individual components or tools with high internal and external geometric complexity for individual parts and small batches. However, the quality of top and side surfaces of SLM parts is still unsatisfactory after the process. Therefore, this study focuses on the improvement of the surface quality on copper alloy parts.

scholarly journals Effect of Process Parameters on Residual Stresses, Distortions, and Porosity in Selective Laser Melting of Maraging Steel 300

Metals ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1042 ◽  
Author(s):  
Mugwagwa ◽  
Yadroitsev ◽  
Matope
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Input Parameter ◽  
Scanning Speed ◽  
Metal Powders ◽  
Laser Melting ◽  
Widespread Application

Selective laser melting (SLM) is one of the most well-known additive manufacturing methods available for the fabrication of functional parts from metal powders. Although SLM is now an established metal additive manufacturing technique, its widespread application in industry is still hindered by inherent phenomena, one of which is high residual stresses. Some of the effects of residual stresses – such as warping and thermal stress-related cracking – cannot be corrected by post processing. Therefore, establishing input process parameter combinations that result in the least residual stress magnitudes and related distortions and/or cracking is critical. This paper presents the influence of laser power, scanning speed, and layer thickness on residual stresses, distortions and achievable density for maraging steel 300 steel parts in order to establish the most optimum input parameter combinations. An analysis of the interdependence between process outcomes shows that high residual stress magnitudes lead to high dimensional distortions in the finished parts, whilst porous parts suffer relatively lower residual stresses and associated distortions.

Sign in / Sign up

Export Citation Format

Share Document