Analysis of the machinability when milling AlSi10Mg additively manufactured via laser-based powder bed fusion
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ORIGINAL ARTICLE
Analysis of the machinability when milling AlSi10Mg additively manufactured via laser-based powder bed fusion Marco Zimmermann 1 & Daniel Müller 1 & Benjamin Kirsch 1 & Sebastian Greco 1 & Jan C. Aurich 1 Received: 14 August 2020 / Accepted: 9 November 2020 # The Author(s) 2020
Abstract Laser-based powder bed fusion (L-PBF) is a promising technology for the production of near net–shaped metallic components. The high surface roughness and the comparatively low-dimensional accuracy of such components, however, usually require a finishing by a subtractive process such as milling or grinding in order to meet the requirements of the application. Materials manufactured via L-PBF are characterized by a unique microstructure and anisotropic material properties. These specific properties could also affect the subtractive processes themselves. In this paper, the effect of L-PBF on the machinability of the aluminum alloy AlSi10Mg is explored when milling. The chips, the process forces, the surface morphology, the microhardness, and the burr formation are analyzed in dependence on the manufacturing parameter settings used for L-PBF and the direction of feed motion of the end mill relative to the build-up direction of the parts. The results are compared with a conventionally cast AlSi10Mg. The analysis shows that L-PBF influences the machinability. Differences between the reference and the L-PBF AlSi10Mg were observed in the chip form, the process forces, the surface morphology, and the burr formation. The initial manufacturing method of the part thus needs to be considered during the design of the finishing process to achieve suitable results. Keywords Laser-based powder bed fusion . Milling . Machinability . Surface quality . Surface integrity . Burr formation
1 Introduction In laser-based powder bed fusion (L-PBF), components are produced from a powdery raw material by the defined layerby-layer joining of individual volume elements. This manufacturing principle enables new possibilities for the user with regard to the freedom in design, the manufacturing of highly customized parts, and the tailoring of products to the requirements of particular applications [1–3]. In recent years, intensive research has been carried out to understand the physical principles of L-PBF [4–6] and to study the influence of the process management on the properties of the manufactured components [7–9]. As a result, the degree of maturity of LPBF has been significantly improved. Today, it is used in
* Marco Zimmermann [email protected] 1
Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Gottlieb-Daimler-Str., D-67663 Kaiserslautern, Germany
several industrial sectors not only for prototyping but also for the manufacturing of customized parts [10, 11]. The surface qualities and dimensional accuracies of laserbased powder bed–fused (hereafter also abbreviated as LPBF) parts, however, are usually still insufficient for a direct application of the parts [12, 13]. Depe
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