Surface roughness optimization of hybrid PBF-LB/M-built Inconel 718 using in situ high-speed milling

IF 2.9 3区 工程技术 Q2 AUTOMATION & CONTROL SYSTEMS International Journal of Advanced Manufacturing Technology Pub Date : 2024-03-23 DOI:10.1007/s00170-024-13382-5
David Sommer, Simon Hornung, Cemal Esen, Ralf Hellmann
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Abstract

We report on the optimization of the surface roughness of hybrid additive manufactured Ni superalloys, combining a conventional laser powder bed fusion process with in situ high-speed milling. This remarkable hybrid approach has only recently been applied to different steel types and barely to Ni superalloys which opposite to steel appear to be challenging for milling processes, particularly within the powderbed of laser powder bed fusion. Different influencing factors on the surface roughness are varied in this study, following the Taguchi method. Their effect is evaluated with respect to the average surface roughness and the maximum surface roughness. The signal-to-noise ratio for the varied parameters infeed, z-pitch, feed rate, and spindle speed is calculated, determining their relevance on the surface roughness, and defining an optimal parameter combination. As the surface quality is optimized to \(\varvec{R_a=0.47\, \mu m}\), the definition of the optimal parameter combination is of the highest relevance for the application of this novel manufacturing approach for Inconel. Using linear regression, the resulting surface roughness of these parameters is predicted, getting validated by the experimental evaluation. Due to a further analysis, including EDX analysis and a quantitative element analysis at different positions of the flank of the milling cutter, wear characteristics as well as the dissipation of the coating of the milling cutter are detected. The flank wear and the resulting breakage of the cutting edge are defined as the main reasons of a rising surface roughness.

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利用原位高速铣削优化混合 PBF-LB/M-Bilt Inconel 718 的表面粗糙度
我们报告了混合添加剂制造镍超合金表面粗糙度的优化,该方法结合了传统的激光粉末床熔融工艺和原位高速铣削工艺。这种非凡的混合方法最近才应用于不同类型的钢材,而且几乎没有应用于镍超合金,因为与钢材相比,镍超合金似乎对铣削工艺具有挑战性,尤其是在激光粉末床熔融的粉末床内。本研究采用田口方法,改变了表面粗糙度的不同影响因素。评估了这些因素对平均表面粗糙度和最大表面粗糙度的影响。通过计算进给、Z 间距、进给率和主轴转速等不同参数的信噪比,确定它们对表面粗糙度的影响,并确定最佳参数组合。由于表面质量的优化目标是 \(\varvec{R_a=0.47\, \mu m}\),因此定义最佳参数组合对于应用这种用于铬镍铁合金的新型制造方法具有最高的相关性。使用线性回归法预测了这些参数产生的表面粗糙度,并通过实验评估进行了验证。通过进一步的分析,包括对铣刀侧面不同位置的 EDX 分析和定量元素分析,可以检测出铣刀的磨损特征和涂层耗散情况。侧面磨损和由此导致的切削刃断裂被定义为表面粗糙度上升的主要原因。
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来源期刊
CiteScore
5.70
自引率
17.60%
发文量
2008
审稿时长
62 days
期刊介绍: The International Journal of Advanced Manufacturing Technology bridges the gap between pure research journals and the more practical publications on advanced manufacturing and systems. It therefore provides an outstanding forum for papers covering applications-based research topics relevant to manufacturing processes, machines and process integration.
期刊最新文献
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