Dimensional accuracy of internal cooling channel made by selective laser melting (SLM) And direct metal laser sintering (DMLS) processes in fabrication of internally cooled cutting tools

Ghani, Saiful Anwar Che; Zakaria, Mohd Hafizu; Harun, Wan Sharuzi Wan; Zaulkafilai, Zuriadi

doi:10.1051/matecconf/20179001058

Cited by 22 publications

(5 citation statements)

References 20 publications

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“…The mesh accuracy was given with 0.002 mm probing error form and 0.004 mm sphere distance error. These values are already significantly larger than typical surface roughness values for powder bed printed metal parts [5,6] and the expected inaccuracies resulting from the manufacturing method in general and imaging via CT. Because of this, we will neglect these errors from now on and assume the optical scans to be perfectly accurate. The turbine blade varies widely in wall thickness and feature size.…”

Section: Imaging and Generation Of Reference Geometrymentioning

confidence: 75%

Error Investigations for a CT and Additive Manufacturing based Reverse Engineering Workflow

Bauer¹,

Schrapp²,

Szijarto³

2019

eJNDT

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A typically occurring task when maintaining gas turbines is the replacement of broken or worn out turbine blades. In order to shorten costly downtimes, it is essential to provide spare parts with minimal lead time; this can turn out problematic in particular for older devices for which blueprints or type designations are not readily available. To overcome this limitation, reverse engineering (RE) methods can provide a remedy, since a geometrical representation of the piece can be obtained at short notice. Due to advances in additive manufacturing (AM) based production, it is also possible to print complex shapes with little additional effort. We present a framework that uses reverse engineering based on Computed Tomography (CT) and optical scanning to obtain the geometry of an AM-printed turbine blade test part and produces a duplicate thereof via the same fabrication technique. To verify the feasibility of the applied RE and manufacturing methods in practice, aberration of both procedures were investigated separately. Combining the results allowed us to review the replicated spare part for geometrical conformance with both, the original turbine blade and the initial design for the part. For this purpose we rely on a simplified approach based on standard deviation and shift of the mean value of error distributions that are obtained by comparing two known geometries to one another. We found that our workflow is capable of deriving the original part’s shape with adequate accuracy and offers the capability for obtaining a good baseline geometry that can be used for further treatment. The framework used is also able to provide meaningful information concerning manufacturing and imaging quality and quantify occurring aberrations of the workpiece. The replica itself exhibits acceptable geometrical deviations for actual productive service when compared to the initial design as well as the original part.

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Section: Imaging and Generation Of Reference Geometrymentioning

confidence: 75%

Error Investigations for a CT and Additive Manufacturing based Reverse Engineering Workflow

Bauer¹,

Schrapp²,

Szijarto³

2019

eJNDT

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“…Other authors have reported precisions under 10 µm (Ghani et al , 2016; Kamarudin et al , 2016), but there is no SLM fabrication study that reports accuracies of 1-3 µm. The hole array positioning of the ion optics requires tolerances under 10 µm, so SLM can fulfill this requirement for the most lax cases (tolerances close to 10 µm), but not for the strictest (tolerances close to 1-3 µm).…”

Section: Results Evaluation and Discussionmentioning

confidence: 99%

Rapid fabrication of ion optics by selective laser melting

Sangregorio

Wang

Xie

et al. 2019

RPJ

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Purpose Traditional ion optics manufacturing processes are complex and costly. The purpose of this paper is to study the feasibility of using selective laser melting (SLM) to produce additively manufactured ion optics. Design/methodology/approach An SLM machine was used to generate Ti6Al4V screen grids. The output was separated through wire cutting from the build platform and studied through a scanning electron microscope. To increase the geometrical accuracy of the original grid, samples consisting of nine-aperture arrays were fabricated with different parameter combinations, increasing the energy density. An empirical method to correlate the energy density applied in the fabrication process with the dimensional accuracy of the hole array positioning was developed through the analysis of multiple samples. Findings The SLM machine generated grids with optimal microstructure, the apertures fell within the specified tolerances and tolerances of slightly less than 10 µm can be guaranteed for the hole array positioning. The grids’ upper surfaces presented good-quality surface finish, and the lower surface quality was acceptable when the wire cutting process that separated the grid from the build platform performed slowly. Regardless of the build strategy, the stresses generated in the separation process caused the warping of the ion optic, so a flattening operation was necessary in all cases. Originality/value This research proved that SLM is a viable solution for ion optics fabrication, faster (less than 24 h) and less expensive (order of US$300) than traditional fabrication methods (with fabrication times from 24 to more than 400 h and costs from US$500 to US$5,000, depending on the material, size and shape).

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“…Ghani et al [50] in their research consider that the issue in improving the design of the internally cooled cutting tool is that the internally cooled cutting tool cannot be manufactured by using a conventional machine due to the complex shape of the cooling channel. In the research [50], [51] the use of additive manufacturing technologies in the manufacturing of ICCT was studied, concluding that: the selective laser melting (SLM) process provided higher precision and had a better surface roughness than the direct metal laser sintering (DMLS) process, but, the DMLS process performed better in dimensional accuracy than SLM [50]; and that the SLM could produce ICCT with high relative density (99 %) and low surface roughness (4.61 μm), showing minimum microstructure defects that encouraged the internal channel design [51]. The availability of modern machining and manufacturing technologies, accurate measuring instruments, precise computing and simulating software allows reaching the designed accuracy of the CT, establishing a tool condition monitoring system for adjustment of the operating parameters in real time, and development of smart cutting tools.…”

Section: Major Trends Of Design Of the Closed-loop Internally Cooled ...mentioning

confidence: 99%

The Design and Performance of Internally Cooled Cutting Tools for Turning: A Literature Review

Korenkovs,

Gerins,

Kromanis

2023

Latvian Journal of Physics and Technical Sciences

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Near–dry machining and dry machining lead to increased temperature of the cutting tools. To reduce tool wear and extend the tool lifetime, and, eventually, to keep the accuracy of manufactured parts within acceptable limits as long as possible, a sustainable cooling technique is required. The technology of internal cooling of the cutting tool appears to be the most promising, because it allows eliminating the presence of the coolant on the manufacturing part and delivers the heat–transferring fluid to the very cutting area of the tool. This paper provides a literature review on the closed–loop internally cooled cutting tools (CLICCT) for turning. The current level of knowledge and experimental machining with prototypes has proven that CLICCT can utilize the benefits of dry cooling, having a longer tool life.

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Dimensional accuracy of internal cooling channel made by selective laser melting (SLM) And direct metal laser sintering (DMLS) processes in fabrication of internally cooled cutting tools

Cited by 22 publications

References 20 publications

Error Investigations for a CT and Additive Manufacturing based Reverse Engineering Workflow

Error Investigations for a CT and Additive Manufacturing based Reverse Engineering Workflow

Rapid fabrication of ion optics by selective laser melting

The Design and Performance of Internally Cooled Cutting Tools for Turning: A Literature Review

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