Metallic cutting inserts fabrication by means of additive manufacturing with fused filament fabrication technology

IF 6 Q1 ENGINEERING, MULTIDISCIPLINARY Results in Engineering Pub Date : 2024-11-04 DOI:10.1016/j.rineng.2024.103194
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Abstract

The present work developed a first approach to the manufacturing of turning inserts using the emerging Additive Manufacturing (AM) technology, specifically employing the fused filament fabrication (FFF) process, based on the extrusion of material and deposition layer by layer. Traditionally, this type of cutting tools were manufactured by powder metallurgy and machining processes, but in this instance Additive Manufacturing processes allowed the customisation of the geometries and eliminated the need of dies to manufacture these tools, leading to economic savings. The study analysed, from different perspectives, the viability of these interchangeable inserts as cutting tools. These approaches included qualitative studies of chip formation and cutting-edge wear as well as thermal and roughness analysis of specimens tested under different conditions. The behaviour of H13 Tool Steel cutting inserts on cylindrical specimens of EN AW-2030 aluminium alloy was compared with commercial carbide inserts, being observed that the chip types produced were extremely similar between those obtained by commercial and those from Additive Manufacturing, particularly in dry conditions. The qualitative study of insert wear showed that AM inserts presented overall larger contribution of built-up edge (BUE) and plastic deformation of the tip, with greater incidence at cutting speeds of Vc = 60 m/min and feed rate of fz = 0.1 mm/r. Regarding thermal analysis, the AM inserts revealed a slightly more abrasive behaviour, resulting in a temperature increase throughout the machining process of approximately 70 °C, with no significant influence from the increase in cutting speed. The study of the surface finish offered average roughness results (Ra) of 0.58 µm for commercial inserts, 1.78 µm in AM inserts with dry tests and 2.06 µm in this same type of insert but tested with lubrication. These variations in average roughness were not significant.
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利用熔融长丝制造技术的增材制造方法制造金属切削刀片
本研究利用新兴的增材制造(AM)技术,特别是采用基于材料挤压和逐层沉积的熔融长丝制造(FFF)工艺,开发了第一种制造车削刀片的方法。传统上,这种类型的切削工具是通过粉末冶金和机械加工工艺制造的,但在这种情况下,增材制造工艺允许定制几何形状,并消除了制造这些工具所需的模具,从而节省了经济成本。研究从不同角度分析了这些可互换刀片作为切削工具的可行性。这些方法包括对切屑形成和切削刃磨损的定性研究,以及在不同条件下测试试样的热分析和粗糙度分析。将 H13 工具钢切削刀片在 EN AW-2030 铝合金圆柱形试样上的表现与商用硬质合金刀片进行了比较,发现商用刀片和快速成型制造刀片产生的切屑类型极为相似,尤其是在干燥条件下。对刀片磨损的定性研究表明,AM 刀片的刀尖堆积刃(BUE)和塑性变形总体上更大,在切削速度 Vc = 60 m/min 和进给量 fz = 0.1 mm/r 时发生率更高。在热分析方面,AM 刀片的磨损性稍强,导致整个加工过程中的温度上升约 70 °C,而切削速度的提高对其影响不大。对表面光洁度的研究结果表明,商用刀片的平均粗糙度(Ra)为 0.58 微米,AM 刀片的干燥测试结果为 1.78 微米,同类型刀片的润滑测试结果为 2.06 微米。平均粗糙度的这些变化并不显著。
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来源期刊
Results in Engineering
Results in Engineering Engineering-Engineering (all)
CiteScore
5.80
自引率
34.00%
发文量
441
审稿时长
47 days
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