“…Lizzu et al also report adhered material on the surface in discordant meso-machining on tilted surfaces with a ballend mill. They attribute the defect to the difficulty of efficiently evacuating the chip in this type of strategy [16].…”
An experimental exploration research and comparison of the residual stress state between micro- and meso-milling processes with a ball-end mill on the Ti-6Al-4V titanium alloy were carried out. The residual stress state was analyzed based on the chip formation process according to the lead and tilt angles of the tool axis in relation to the normal vector to the surface. A novel idea was proposed to study the characteristic kinematics of a five-axis machining process, in a three-axis vertical machining center. When using the up-milling cutting strategy, it was found the defect of smeared/adhered material to the surface occurs in both the micro- and meso-milling levels, associated with the build-up edge and build-up layer phenomenon. The stress tensor of the surface was obtained using the X-ray diffraction technique. The down-milling cutting strategy produced the best surface finish and higher compressive residual stresses. Higher compressive residual stresses were found in the feed direction than in the cross-feed direction. The micro-milling process produced higher compressive residual stresses than those observed in the meso-milling process.
“…Lizzu et al also report adhered material on the surface in discordant meso-machining on tilted surfaces with a ballend mill. They attribute the defect to the difficulty of efficiently evacuating the chip in this type of strategy [16].…”
An experimental exploration research and comparison of the residual stress state between micro- and meso-milling processes with a ball-end mill on the Ti-6Al-4V titanium alloy were carried out. The residual stress state was analyzed based on the chip formation process according to the lead and tilt angles of the tool axis in relation to the normal vector to the surface. A novel idea was proposed to study the characteristic kinematics of a five-axis machining process, in a three-axis vertical machining center. When using the up-milling cutting strategy, it was found the defect of smeared/adhered material to the surface occurs in both the micro- and meso-milling levels, associated with the build-up edge and build-up layer phenomenon. The stress tensor of the surface was obtained using the X-ray diffraction technique. The down-milling cutting strategy produced the best surface finish and higher compressive residual stresses. Higher compressive residual stresses were found in the feed direction than in the cross-feed direction. The micro-milling process produced higher compressive residual stresses than those observed in the meso-milling process.
“…The result of this study is that the low viscosity MQL type contributes greatly in reducing waste and minimizing roughness (Ra). Lizzul, et al [16] evaluated the surface quality (Ra) of Ti6AI4V titanium alloy by flexibility ball end milling. The variations used were surface topography, cutting force, and chip morphology.…”
In the manufacturing industry, machining has developed quite rapidly from the use of conventional machines to unconventional machines. Unconventional machines that are often used today are optimize computer numerically controlled (CNC), the use of CNC in the manufacturing industry provides many benefits in product quality and productivity. One of them is CNC milling, this type is one of the main machines on the production floor. Machining optimization becomes the main goal to achieve the ideal response in order to produce products with good and consistent quality and productivity. Surface quality leads to surface roughness, while productivity leads to material removal rate. This study aims to optimize CNC milling machining parameters on AA6061 with Taguchi experimental design and preference ranking organization method for enrichment evaluation (PROMETHEE) method. Machining was controlled using wet machining conditions to maintain temperature during machining. Experiments were conducted nine times with three factors and levels. These factors included spindle speed, feed rate, and depth of cut. The result of this research is the ideal value of the combination of surface roughness and material burning rate which is 0.565 (experiment 3). This best experiment is influenced by spindle speed 2600 rpm, feed rate 65 mm/min, and depth of cut 2.5 mm. Feed rate has the largest contribution in influencing the response which is 43.23%, followed by depth of cut 25.24%, and spindle speed 15.91%.
“…Chemical-based polishing tends to impair the fatigue strength of MAM parts due to the weakened/dissolved thin structures in the parts [14]. Figure 1 Post-processing surface treatments of MAM parts [35-38]. …”
The application of Metal Additive Manufacturing (MAM) in the aerospace industry has been gaining attention. The poor surface quality of parts greatly limits the prospects of MAM-produced parts in the aerospace industry as fatigue performance hinges on a good surface finish and homogeneous microstructure. Post-processing treatments are important to improve the surface quality and the overall performance of MAM-produced parts during static and dynamic loadings. This paper provides a review of the current state of post-processing treatment options for MAM-produced parts. The advances in the post-processing treatments of MAM parts to improve fatigue strength, tensile strength, surface integrity and other properties of parts are reviewed. Future research prospects on metal additive manufacturing of aerospace parts are briefly expounded. Abbreviations: AM: Additive Manufacturing; CMT-WAAM: Cold Metal Transfer-Based Wire Arc Additive Manufacturing; CSD: Cold Spray Deposition; DA: Direct Aging; DED: Directed Energy Deposition; E: Elongation; EBAM: Wire-feed Electron Beam Additive Manufacturing; EBAM Electron Beam Additive Manufacturing; EBSD: Electron Back Scattered Diffraction; FRAM: Friction Rolling Additive Manufacturing; FSAM: Friction Stir Additive Manufacturing; FSP: Friction Stir Processing; HFDB: Hybrid Friction Diffusion Bonding; HIP: Hot Isostatic Pressing; HSA Homogenisation + Solution Treatment + Aging; IFSP: Interlayer Friction Stir Processing; IPF: Inverse Pole Figure; KAM: Kernel Average Misorientation; LAM: Laser Additive Manufacturing Process; LENS: Laser Engineered Net Shaping; LDM: Laser Deposition Manufacturing; L-PBF: Laser Powder Bed Fusion; MAM: Metal Additive Manufacturing; MTFS: Multi-track Multi-layer Friction Surfacing; O-WLAM: Wire Oscillating Laser Additive Manufacturing (O-WLAM); S: Solution Treatment; SA: Solution Treatment + aging; TEM: Transmission Electron Microscope; UAM: Ultrasonic Additive Manufacturing; UTS: Ultimate Tensile Strength; WAAM: Wire Arc Additive Manufacturing; YS: Yield Strength
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