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Surface Finish Processes of Additively Manufactured Metal Parts

Year 2020, Volume: 12 Issue: 1, 45 - 55, 16.06.2020

Abstract

Additive Manufacturing (AM)
offers the possibility of manufacturing of parts with complex geometries which
are not possible to be manufactured by conventional machining processes. Since
it is likely to manufacture geometry-free parts as a single element, which have
similar mechanical properties compared to their counterparts manufactured by
machining or plastic deformation methods, AM methods grown very popular
recently.

Although AM methods have lots of
advantages, there are also some disadvantages concerning surface quality. Parts
with low fatigue strength due to their bad surface quality can not offer high
performance under dynamic load conditions. For this reason, additively manufactured
parts should be subjected to surface finish processes in order to eliminate
surface roughness.





In this work, surface finish
processes that are applied to additively manufactured metal parts, for the
purpose of surface roughness elimination thus fatigue strength increase, have
been explained.

References

  • Berenji K.R, Karagüzel U, Özlü E, Budak E. (2019). Effects of turning milling conditions on chip formation and surface finish. CIRP Annals, Volume 68, Issue 1, 113-116.Bordatchev E, Hafiz A.M.K, Tutunea-Fatan O.R. (2014). Performance of laser polishing in finishing of metallic surfaces. Int J Adv Manuf Technol, 73, 35–52.Gora W.S, Tian Y, Cabo A.B, Ardron M, Maier R.R.J, Prangnell P, Weston N.J, Hand D.P. (2016). Enchancing surface finish of additively manufactured titanium and cobalt chrome elements user laser based finishing. 9th International Conference on Photonic Technologies. Physics Procedia 83, 258 – 263.Grimm T, Wiora G, Witt G. (2015). Characterization of typical surface effects in additive manufacturing with confocal microscopy. Surf Topogr Metrol Prop, 3(1).Haosheng C, Jiadao W, Darong C. (2009). Cavitation damages on solid surfaces in suspensions containing spherical and irregular particles. Wear, Volume 266, Issue 5, 345-348.Hemaid A, Tawfeek T, Ibrahim A.A. (2016). Experimental Investigation on Surface Finish During Turning of Aluminum Under Dry and Minimum Quantity Lubrication Machining Conditions. American Journal of Materials Engineering and Technology, Vol. 4, No. 1, 1-5.Hua Y, Liu Z. (2018). Effects of cutting parameters and tool nose radius on surface roughness and work hardening during dry turning Inconel 718. The International Journal of Advanced Manufacturing Technology, Vol 96, No 3.Ippolito R, Iuliano L, Gatto A. (1995). Benchmarking of Rapid Prototyping Techniques in Terms of Dimensional Accuracy and Surface Finish. CIRP Annals - Manufacturing Technology, 44, 157-60.Krishnan A, Fang F. (2019). Review on mechanism and process of surface polishing using lasers. Front. Mech. Eng.14(3), 299–319.Kumar N.S, Shetty A, Shetty A, Ananth K, Shetty H. (2012). Effect of spindle speed and feed rate on surface roughness of Carbon Steels in CNC turning. Procedia Engineering 38, 691 – 697.Kuram E, Özçelik B, Demirbaş E, Şık E (2010). Effects of the Cutting Fluid Types and Cutting Parameters on Surface Roughness and Thrust Force. Proceedings of the World Congress on Engineering, Vol II.Lebaraj A.V, Kumar T.S, Kumar L.A, Deepak C.R. (2017). Influence of shot peening on surface quality of austenitic and duplex stainless steel. IOP Conf. Series: Materials Science and Engineering 263.Lee H, Lee D, Jeong H. (2016). Mechanical Aspects of the Chemical Mechanical Polishing Process: A Review. International Journal Of Precision Engineerıng And Manufacturıing Vol. 17, No. 4, 525-536.Łyczkowska E, Szymczyk P, Dybała B, Chlebus E. (2014). Chemical polishing of scaffolds made of Ti–6Al–7Nb alloy by additive manufacturing. Arch Civil Mech Eng 14, 586–594.Ma C.P, Guan Y.C, Zhou W. (2017). Laser polishing of additively manufactured Ti alloys. Optics and Lasers in Engineering 93, 171–177.Melchels P.W, Domingos A.N, Klein T.J, Malda J, Bartolo B.J, Hutmacher D.W. (2012). Additive manufacturing of tissues and organs. Progress in Polymer Science, 37, 1079– 1104.Mohammadian N, Turenne S, Brailovski V. (2018). Surface finish control of additively-manufactured Inconel 625 components using chemical-abrasive flow polishing. Journal of Materials Processing Tech. 252, 728–738.Nüsser C, Sänker H, Willenboeg E. (2013). Pulsed laser micro polishing of metals using dual-beam technology. Physics Procedia 41, 346 – 355.Pečnik P, Hočevar M, Širok B, Bizjan B. (2016).Scale deposit removal by means of ultrasonic cavitation. Wear, 356–357, 45–52.Preußner J, Oeser S, Pfeiffer W. (2014). Microstructure and residual stresses of laser structured surfaces. Advanced Materials Research,, 996: 568–573.Pyka G, Burakowski A, Kerckhofs G, Moesen M, Van Bael S, Schrooten J. (2012). Surface modification of Ti6Al4V open porous structures produced by additive manufacturing. Adv Eng Mater 14, 363–370.Ratnam M.M. (2017). Factors Affecting Surface Roughness in Finish Turning. Comprehensive Material Finishing. Volume 1, 1-25Saravankumar A, Dhanabal S, Jayanand E, Logeshwaran P. (2018). Analysis of Process Parameters in Surface Grinding Process. Materials Today: Proceedings 5, 8131–8137.Selvaraj D.P, Chandramohan P, Mohanraj M. (2017). Optimization of surface roughness, cutting force and tool wear of nitrojen alloyed dublex stainless steel in dry turning process using Taguchi method. Measurement 49, 205-215Sherillo F. (2019). Chemical surface finishing of AlSi10Mg components made by addtitive manufacturing. Manufacturing Letters 19, 5–9.Tan K.L, Yeo S.H. (2017). Surface modification of addit6ive manufactured components by ultrasonic cavitation abrasive finishing. Wear, 378-379, 90–95.Temmler A, Willenborg E, Wissenbach K. (2012). Laser Polishing. Proceedings of SPIE - The International Society for Optical Engineering.Tzanakis I, Eskin D.G, Georgoulas A, Fytanidis D.K. (2014). Incubation pit analysis and calculation of the hydrodynamic impact pressure from the implosion of an acoustic cavitation bubble. Ultrason, Sonochem, 21(2), 866–878.Ukar E, Lamikiz A, Lopez de Lacalle L.N. (2010). Laser polishing parameter optimisation on selective laser sintered parts. Int. J. Machining and Machinability of Materials, Vol. 8, Nos. ¾.Ukar E, Lamikiz A, Liebana F, Martinez S, Tabernero I. (2015). An industrial approach of laser polishing with different laser sources. Mater Werkst, 46:661–7.Xavior, M. A.; Adithan, M. (2009). Determining the Influence of Cutting Fluids on Tool Wear and Surface Roughness During Turning of AISI 304 Austenitic Stainless Steel. J Mater. Proc. Tech. 209 (2); 900–909.Yung K.C, Xiao T.Y, Choy H.S, Wang W.J, Cai Z.X. (2018). Laser polishing of additive manufactured CoCr alloy components with complex surface geometry. Journal of Materials Processing Tech. 262, 53–64.Zadpoor A.A, Malda J. (2017). Additive Manufacturing of Biomaterials, Tissues, and Organs. Annals of Biomedical Engineering, Vol 45, No 1, 1–11.Zhihao F, Libin L, Longfei C, Yingchun G. (2018). Laser Polishing of Additive Manufactured Superalloy. 4th CIRP Conference on Surface Integrity (CSI 2018). Procedia CIRP 71, 150-154.

EKLEMELİ İMALAT İLE İMAL EDİLMİŞ METAL PARÇALARIN YÜZEY BİTİRME İŞLEMLERİ

Year 2020, Volume: 12 Issue: 1, 45 - 55, 16.06.2020

Abstract

Eklemeli İmalat (Eİ) yöntemleri,
talaşlı imalat gibi geleneksel yöntemlerle imalatı mümkün olmayan karmaşık
geometrili parçaların imalatında kolaylık sağladığı için son yıllarda oldukça
popüler hale gelmiştir. Zira bu yöntemler sayesinde söz konusu karmaşık
geometrili parçaların yekpare olarak imalatının mümkün olması, ayrıca imal
edilen parçaların mekanik özelliklerinin talaşlı imalat ya da plastik şekil
verme yöntemleri ile imal edilmiş versiyonlarına oldukça yakın olması da
Eklemeli İmalat yöntemlerinin yaygınlığını pekiştirmiştir.



Eklemeli İmalat yöntemleri her ne
kadar birçok avantaja sahip olsa da, başta düşük yüzey kalitesi olmak üzere
bazı dezavantajları da mevcuttur. Düşük yüzey kalitesi neticesinde yorulma
dayanımları olumsuz etkilenen parçalar, dinamik yüklerin söz konusu olduğu
çalışma ortamlarında arzu edilen performansı sergileyememektedir. Bu sebeple,
eklemeli imalat ile imal edilmiş parçaların imalat sonrası ikinci işlemlere
tabii tutularak yüzeylerindeki pürüzlülükler giderilmelidir.



Bu çalışmada, eklemeli imalat ile
imal edilmiş metal parçaların yorulma dayanımını arttırmak için, imalat sonrası
uygulanan yüzey kalitesini arttırıcı bitirme işlemleri anlatılmaktadır. 

References

  • Berenji K.R, Karagüzel U, Özlü E, Budak E. (2019). Effects of turning milling conditions on chip formation and surface finish. CIRP Annals, Volume 68, Issue 1, 113-116.Bordatchev E, Hafiz A.M.K, Tutunea-Fatan O.R. (2014). Performance of laser polishing in finishing of metallic surfaces. Int J Adv Manuf Technol, 73, 35–52.Gora W.S, Tian Y, Cabo A.B, Ardron M, Maier R.R.J, Prangnell P, Weston N.J, Hand D.P. (2016). Enchancing surface finish of additively manufactured titanium and cobalt chrome elements user laser based finishing. 9th International Conference on Photonic Technologies. Physics Procedia 83, 258 – 263.Grimm T, Wiora G, Witt G. (2015). Characterization of typical surface effects in additive manufacturing with confocal microscopy. Surf Topogr Metrol Prop, 3(1).Haosheng C, Jiadao W, Darong C. (2009). Cavitation damages on solid surfaces in suspensions containing spherical and irregular particles. Wear, Volume 266, Issue 5, 345-348.Hemaid A, Tawfeek T, Ibrahim A.A. (2016). Experimental Investigation on Surface Finish During Turning of Aluminum Under Dry and Minimum Quantity Lubrication Machining Conditions. American Journal of Materials Engineering and Technology, Vol. 4, No. 1, 1-5.Hua Y, Liu Z. (2018). Effects of cutting parameters and tool nose radius on surface roughness and work hardening during dry turning Inconel 718. The International Journal of Advanced Manufacturing Technology, Vol 96, No 3.Ippolito R, Iuliano L, Gatto A. (1995). Benchmarking of Rapid Prototyping Techniques in Terms of Dimensional Accuracy and Surface Finish. CIRP Annals - Manufacturing Technology, 44, 157-60.Krishnan A, Fang F. (2019). Review on mechanism and process of surface polishing using lasers. Front. Mech. Eng.14(3), 299–319.Kumar N.S, Shetty A, Shetty A, Ananth K, Shetty H. (2012). Effect of spindle speed and feed rate on surface roughness of Carbon Steels in CNC turning. Procedia Engineering 38, 691 – 697.Kuram E, Özçelik B, Demirbaş E, Şık E (2010). Effects of the Cutting Fluid Types and Cutting Parameters on Surface Roughness and Thrust Force. Proceedings of the World Congress on Engineering, Vol II.Lebaraj A.V, Kumar T.S, Kumar L.A, Deepak C.R. (2017). Influence of shot peening on surface quality of austenitic and duplex stainless steel. IOP Conf. Series: Materials Science and Engineering 263.Lee H, Lee D, Jeong H. (2016). Mechanical Aspects of the Chemical Mechanical Polishing Process: A Review. International Journal Of Precision Engineerıng And Manufacturıing Vol. 17, No. 4, 525-536.Łyczkowska E, Szymczyk P, Dybała B, Chlebus E. (2014). Chemical polishing of scaffolds made of Ti–6Al–7Nb alloy by additive manufacturing. Arch Civil Mech Eng 14, 586–594.Ma C.P, Guan Y.C, Zhou W. (2017). Laser polishing of additively manufactured Ti alloys. Optics and Lasers in Engineering 93, 171–177.Melchels P.W, Domingos A.N, Klein T.J, Malda J, Bartolo B.J, Hutmacher D.W. (2012). Additive manufacturing of tissues and organs. Progress in Polymer Science, 37, 1079– 1104.Mohammadian N, Turenne S, Brailovski V. (2018). Surface finish control of additively-manufactured Inconel 625 components using chemical-abrasive flow polishing. Journal of Materials Processing Tech. 252, 728–738.Nüsser C, Sänker H, Willenboeg E. (2013). Pulsed laser micro polishing of metals using dual-beam technology. Physics Procedia 41, 346 – 355.Pečnik P, Hočevar M, Širok B, Bizjan B. (2016).Scale deposit removal by means of ultrasonic cavitation. Wear, 356–357, 45–52.Preußner J, Oeser S, Pfeiffer W. (2014). Microstructure and residual stresses of laser structured surfaces. Advanced Materials Research,, 996: 568–573.Pyka G, Burakowski A, Kerckhofs G, Moesen M, Van Bael S, Schrooten J. (2012). Surface modification of Ti6Al4V open porous structures produced by additive manufacturing. Adv Eng Mater 14, 363–370.Ratnam M.M. (2017). Factors Affecting Surface Roughness in Finish Turning. Comprehensive Material Finishing. Volume 1, 1-25Saravankumar A, Dhanabal S, Jayanand E, Logeshwaran P. (2018). Analysis of Process Parameters in Surface Grinding Process. Materials Today: Proceedings 5, 8131–8137.Selvaraj D.P, Chandramohan P, Mohanraj M. (2017). Optimization of surface roughness, cutting force and tool wear of nitrojen alloyed dublex stainless steel in dry turning process using Taguchi method. Measurement 49, 205-215Sherillo F. (2019). Chemical surface finishing of AlSi10Mg components made by addtitive manufacturing. Manufacturing Letters 19, 5–9.Tan K.L, Yeo S.H. (2017). Surface modification of addit6ive manufactured components by ultrasonic cavitation abrasive finishing. Wear, 378-379, 90–95.Temmler A, Willenborg E, Wissenbach K. (2012). Laser Polishing. Proceedings of SPIE - The International Society for Optical Engineering.Tzanakis I, Eskin D.G, Georgoulas A, Fytanidis D.K. (2014). Incubation pit analysis and calculation of the hydrodynamic impact pressure from the implosion of an acoustic cavitation bubble. Ultrason, Sonochem, 21(2), 866–878.Ukar E, Lamikiz A, Lopez de Lacalle L.N. (2010). Laser polishing parameter optimisation on selective laser sintered parts. Int. J. Machining and Machinability of Materials, Vol. 8, Nos. ¾.Ukar E, Lamikiz A, Liebana F, Martinez S, Tabernero I. (2015). An industrial approach of laser polishing with different laser sources. Mater Werkst, 46:661–7.Xavior, M. A.; Adithan, M. (2009). Determining the Influence of Cutting Fluids on Tool Wear and Surface Roughness During Turning of AISI 304 Austenitic Stainless Steel. J Mater. Proc. Tech. 209 (2); 900–909.Yung K.C, Xiao T.Y, Choy H.S, Wang W.J, Cai Z.X. (2018). Laser polishing of additive manufactured CoCr alloy components with complex surface geometry. Journal of Materials Processing Tech. 262, 53–64.Zadpoor A.A, Malda J. (2017). Additive Manufacturing of Biomaterials, Tissues, and Organs. Annals of Biomedical Engineering, Vol 45, No 1, 1–11.Zhihao F, Libin L, Longfei C, Yingchun G. (2018). Laser Polishing of Additive Manufactured Superalloy. 4th CIRP Conference on Surface Integrity (CSI 2018). Procedia CIRP 71, 150-154.
There are 1 citations in total.

Details

Primary Language Turkish
Journal Section Derleme Makaleler
Authors

Tolgahan Ermergen

Fatih Taylan

Publication Date June 16, 2020
Published in Issue Year 2020 Volume: 12 Issue: 1

Cite

IEEE T. Ermergen and F. Taylan, “EKLEMELİ İMALAT İLE İMAL EDİLMİŞ METAL PARÇALARIN YÜZEY BİTİRME İŞLEMLERİ”, IJTS, vol. 12, no. 1, pp. 45–55, 2020.

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