Determining the machining allowance for WAAM parts

Fuchs, Christina; Baier, Daniel; Semm, Thomas; Zaeh, Michael F.

doi:10.1007/s11740-020-00982-9

Cited by 31 publications

(16 citation statements)

References 13 publications

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“…As the difference in occurring residual stresses within deposited weld metal is commonly known, this should be considered for further residual stresses evaluation, especially in a condition without PWHT. And there would be another problem being taken into account, a significant component distortion or deformation due to the release of residual stresses during machining [4,34].…”

Section: Discussionmentioning

confidence: 99%

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Schroepfer

Treutler

Boerner

et al. 2021

Int J Adv Manuf Technol

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The supply and processing of materials for highly stressed components are usually cost-intensive. Efforts to achieve cost and resource efficiency lead to more complex structures and contours. Additive manufacturing steps for component repair and production offer significant economic advantages. Machining needs to be coordinated with additive manufacturing steps in a complementary way to produce functional surfaces suitable for the demands. Regarding inhomogeneity and anisotropy of the microstructure and properties as well as production-related stresses, a great deal of knowledge is still required for efficient use by small- and medium-size enterprises, especially for the interactions of subsequent machining of these difficult-to-machine materials. Therefore, investigations on these influences and interactions were carried out using a highly innovative cost-intensive NiCrMo alloy (IN725). These alloys are applied for claddings as well as for additive component manufacturing and repair welding using gas metal arc welding processes. For the welded specimens, the adequate solidification morphology, microstructure and property profile were investigated. The machinability in terms of finishing milling of the welded surfaces and comparative analyses for ultrasonic-assisted milling processes was examined focussing on surface integrity. It was shown that appropriate cutting parameters and superimposed oscillating of the milling tool in the direction of the tool rotation significantly reduce the mechanical loads for tool and workpiece surface. This contributes to ensure a high surface integrity, especially when cutting has to be carried out without cooling lubricants.

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Section: Discussionmentioning

confidence: 99%

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Schroepfer

Treutler

Boerner

et al. 2021

Int J Adv Manuf Technol

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“…This process is characterized by high metal deposition capacity and reduced material waste, part cost and iteration time compared with standard processes [2][3][4]. The method consists of depositing molten metal through an electric arc between the nozzle and the already-deposited material in a sequence of two-dimensional (2D) layers using a robot to perform the movements [5]. The quality of the weld bead depends on various parameters, such as the quality of the wire, the wire feed speed (WFS), the travel speed (TS) and the heat input [1].…”

Section: Introductionmentioning

confidence: 99%

“…Fig 5. Toolpath and speed for the semi-circular, rectangular and spiral strategies, as well as for one of the triangular strategies (namely 60°).…”

mentioning

confidence: 99%

Complex Interaction Between CMT Equipment and Robot Controllers During the WAAM Process: Consequences for Toolpath Accuracy

Viola

Balandraud

Poulhaon

et al. 2022

Preprint

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In the WAAM process, the accuracy of the toolpath is of prime importance for the mechanical properties of the final part because of the material defects that could be generated. This paper deals with the motion analysis of the end effector nozzle of a robot dedicated to the WAAM process. The movement of the nozzle to create a rectangular layer was experimentally analyzed without physically depositing material (trajectory definition only). Various strategies, nozzle speeds and layer areas were compared in terms of travel time and length over different sections of the toolpath in order to identify various problems, in particular associated with acceleration and deceleration phases when changing direction. The consequences of a discontinuous deposition were also studied, revealing a complex interaction between cold metal transfer equipment and robot controllers. The results enable a better understanding of this interaction, which is important for deposition quality and performance. Finally, a model was proposed to calculate the manufacturing time of any layer area based on a preliminary identification for a single area.

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“…This is achieved through a higher laser power and a greater wire feed, which in turn result in a greater layer thickness. At the same time, DED processes have a poorer surface quality and lower dimensional accuracy, which leads to a higher volume to be machined [11][12][13][14][15][16].…”

Section: Introductionmentioning

confidence: 99%

Influence of the manufacturing parameters of an AlMg5 wire–based hybrid production process on quality and mechanical properties

Möhring

Becker

Eisseler

et al. 2021

Int J Adv Manuf Technol

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Hybrid manufacturing processes are known for combining the advantages of additive manufacturing and more traditional manufacturing processes such as machining to create components of complex geometry while minimising material waste. The trend towards lightweight design, especially in view of e-mobility, gives aluminium materials an important role to play. This study examines the use of aluminium alloys in laser metal wire deposition (LMWD) processes with subsequent subtractive machining, which is considerably more difficult due to the different process-related influences. The investigations are focussed on the influence of the differently controlled laser power on the shape accuracy, the microstructure, and the hardness of the AlMg5 test components after the LMWD process with subsequent subtractive machining by turning. The long-term goal of the investigations is to increase the stability of the hybrid production process of AlMg5 components with defined dimensional accuracy and mechanical properties.

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Determining the machining allowance for WAAM parts

Cited by 31 publications

References 13 publications

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Complex Interaction Between CMT Equipment and Robot Controllers During the WAAM Process: Consequences for Toolpath Accuracy

Influence of the manufacturing parameters of an AlMg5 wire–based hybrid production process on quality and mechanical properties

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