Analytical force modelling for micro milling additively fabricated Inconel 625
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Analytical force modelling for micro milling additively fabricated Inconel 625 Andrea Abeni1 · Dario Loda1,2 · Tuğrul Özel2 · Aldo Attanasio1 Received: 24 April 2020 / Accepted: 1 September 2020 © German Academic Society for Production Engineering (WGP) 2020
Abstract In recent years, miniaturization of components has been concerned with several industrial fields including aerospace, energy, and electronics. This phenomenon resulted in increasing demand of micro-components with complex shape and high strength, often in high-temperature environment. Nickel-based superalloys such as Inconel 625 are a class of material suitable to aforementioned applications and can be successfully processed with Additive Manufacturing (AM). Moreover, micro-milling can be employed to manufacture micro-scale features on the additively fabricated parts or to achieve better surface finishes, as required for high-precision mechanical assemblies. In micro machining, it is possible to notice a lack of scientific study focusses on the material removal behavior of difficulty-to-cut alloys produced via Additive Manufacturing. This paper describes an analytical cutting force model suitable also for AM’d parts which considers the presence of ploughing- and shearing- dominated cutting regimes. A refinement procedure of the cutting force model was defined and applied by performing an experimental work on Inconel 625 samples fabricated by LaserCUSING™. A search algorithm was employed to develop an iterative methodology to determine the unknown cutting force model parameters. The model was successfully utilized to predict how the cutting force is affected as the process parameters change. Keywords Micro milling · Cutting force model · Nickel-based superalloy · Minimum cutting thickness · Selective laser melting
1 Introduction Additive manufacturing (AM) is a collection of layer-bylayer building processes which can be successfully employed using polymers, ceramics and metals. The type and the aggregate state of the feedstock material as well as the binding mechanism between the overlapped layers must be considered for an AM classification [1]. In AM of metals, the feedstock material is usually provided in the form of powder and an energy source produces the localized melting. It is followed by the subsequent solidification of the added material over the substrate in the form of layers, with a typical thickness ranging between 20 and 150 μm [2, 3]. The most * Aldo Attanasio [email protected] 1
Department of Mechanical and Industrial Engineering, University of Brescia, V. Branze 38, 25123 Brescia, Italy
Manufacturing and Automation Research Laboratory, Industrial and Systems Engineering, Rutgers University, Piscataway, NJ, USA
2
common Additive Manufacturing processes for powder metals are powder bed fusion (PBF) type which includes laser powder bed fusion (L-PBF) and electron beam powder bed fusion (EB-PBF). Furthermore, L-PBF processes are also known with their commercial names such as Selective Laser Melting (
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