A comparative study of dry and cryogenic milling for Directed Energy Deposited IN718 components: effect on process and part quality

Souflas, Thanassis; Bikas, Harry; Ghassempouri, Mani; Salmi, Alessandro; Atzeni, Eleonora; Saboori, Abdollah; Brugnetti, Ivan; Valente, Anna; Mazzucato, Federico; Stavropoulos, Panagiotis

doi:10.1007/s00170-021-08313-7

Cited by 24 publications

(6 citation statements)

References 41 publications

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“…Therefore, this material is used as a worst-case scenario to estimate the cutting forces generated by the process. In addition, cutting forces calculated using aggressive cutting settings to determine the worst-case scenario are as follows [27], based on the specific force coefficients for this material:…”

Section: Load Cases Of the Robotic Cell Framementioning

confidence: 99%

Process-Driven Layout Optimization of a Portable Hybrid Manufacturing Robotic Cell Structure

Bikas,

Manitaras,

Souflas

et al. 2024

Eng

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Hybrid manufacturing combines manufacturing processes (typically additive manufacturing and machining) exploiting the benefits of each and enabling repair scenarios. Such an approach can be integrated with a robot, and if made portable, can form a flexible machine tool that can be easily transported anywhere to enable repairs in the field. However, the design of the load-bearing structure determines its transportability, and its stiffness plays a crucial functional role under dynamic loads and affects the product quality. Finding the right balance between weight and stiffness requires accurate boundary conditions and an effective design. In this work, a method is proposed towards process-driven optimization of a portable manufacturing cell structure. The dynamic cutting forces are determined through a machining process model and, via a simplified model of the robot arm, the forces at the base of the robot are estimated. Since the frame consists of beams, the layout optimization method is applied, using the estimated process forces as boundary conditions to optimize the arrangement of beams. The proposed method achieved 0.05 mm displacement in the load-bearing structure under milling and an acceptable accuracy of the position of a hole’s center during drilling, while the overall weight reduced by 17.6%.

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Section: Load Cases Of the Robotic Cell Framementioning

confidence: 99%

Process-Driven Layout Optimization of a Portable Hybrid Manufacturing Robotic Cell Structure

Bikas,

Manitaras,

Souflas

et al. 2024

Eng

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“…Gerdes et al [253] correlated process signatures obtained from hyperspectral imaging to the surface roughness, thus validating the utility of spectral analysis in metal AM. Moreover, additional electronic and other signals, such as eddy current, thermocouple, optoelectronic sensor, and strain gauge, offer various monitoring capabilities, enhancing the quality control measures in metal AM processes [37,134,135,180,181,185].…”

Section: Spectral and Other Signalsmentioning

confidence: 99%

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

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This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems.

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“…In both studies, the machining of the sections in the FGM containing more IN718 than SS316L led to higher cutting forces and the generation of more cutting heat, owing to the higher hardness and strength of the IN718. New techniques like cryogenic cooling with liquid nitrogen have been effective in significantly reducing the cutting forces and tool wear during the machining of LMDed IN718 [20].…”

Section: Introductionmentioning

confidence: 99%

Dry and Minimum Quantity Lubrication Machining of Additively Manufactured IN718 Produced via Laser Metal Deposition

Ozaner,

Kapil,

Sato

et al. 2023

Lubricants

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Inconel 718 (IN718), a Ni-based superalloy, is immensely popular in the aerospace, nuclear, and chemical industries. In these industrial fields, IN718 parts fabricated using conventional and additive manufacturing routes require subsequent machining to meet the dimensional accuracy and surface quality requirements of practical applications. The machining of IN718 has been a prominent research topic for conventionally cast, wrought, and forged parts. However, very little attention has been given to the machinability of IN718 additively manufactured using laser metal deposition (LMD). This lack of research can lead to numerous issues derived from the assumption that the machining behavior corresponds to conventionally fabricated parts. To address this, our study comprehensively assesses the machinability of LMDed IN718 in dry and minimum quantity lubrication (MQL) cutting environments. Our main goal is to understand how LMD process variables and the cutting environment affect cutting forces, tool wear, surface quality, and energy consumption when working with LMDed IN718 walls. To achieve this, we deposited IN718 on SS309L substrates while varying the following LMD process parameters: laser power, powder feed rate, and scanning speed. The results unveil that machining the deposited wall closer to the substrate is significantly more difficult than away from the substrate, owing to the variance in hardness along the build direction. MQL greatly improves machining across all processing parameters regardless of the machining location along the build direction. Laser power is identified as the most influential parameter, along with the recommendation for a specific combination of power feed rate and scanning speed, providing practical guidelines for optimizing the machining process. While MQL positively impacts machinability, hourly energy consumption remains comparable to dry cutting. This work offers practical guidance for improving the machinability of LMDed IN718 walls and the successful adoption of LMD and the additive–subtractive machining chain. The outcomes of this work provide a significant and critical understanding of location-dependent machinability that can help develop targeted approaches to overcome machining difficulties associated with specific areas of the LMDed structure. The finding that MQL significantly improves machining across all processing parameters, particularly in the challenging bottom region, offers practical guidance for selecting optimal cutting conditions. The potential economic benefits of MQL in terms of tool longevity without a substantial increase in energy costs is also highlighted, which has implications for incorporating MQL in several advanced manufacturing processes.

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A comparative study of dry and cryogenic milling for Directed Energy Deposited IN718 components: effect on process and part quality

Cited by 24 publications

References 41 publications

Process-Driven Layout Optimization of a Portable Hybrid Manufacturing Robotic Cell Structure

Process-Driven Layout Optimization of a Portable Hybrid Manufacturing Robotic Cell Structure

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Dry and Minimum Quantity Lubrication Machining of Additively Manufactured IN718 Produced via Laser Metal Deposition

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