Investigation of machining coolant residue cleaning methods for Ti6Al4V part fabrication through hybrid manufacturing process

Yan, Lei; Zhang, Yunlu; Newkirk, Joseph William; Liou, Frank W.; Thomas, Eric; Baker, Andrew

doi:10.1016/j.mfglet.2018.02.016

Cited by 11 publications

(10 citation statements)

References 10 publications

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“…These findings are in line with the observations reported by Yan et al, which also show the occurrence of pores and cracks when material is deposited on a surface which is contaminated with cooling lubricant residues. The authors also observed a decrease in tensile strength of hybrid manufactured specimens using emulsion cooling compared to reference specimens without coolant if no appropriate cleaning step was performed [35]. It seems conclusive that the existence of defects also might have a negative effect on other component properties such as fatigue behavior.…”

Section: Lmd On Machined Surfacesmentioning

confidence: 88%

“…In the case of material deposition on intermediate machined surfaces without an appropriate cleaning procedure, significant contamination and pronounced cracking were observed. In fact, a multistage cleaning process consisting of laser heating and cleaning with compressed air was applied to ensure a reliable hybrid manufacturing process [35]. A study by Cortina et al using Inconel 718 reported similar results.…”

Section: Introductionmentioning

confidence: 95%

“…Again, deviating from evaporating substances like liquid nitrogen or solid carbon dioxide (dry ice), the use of conventional cooling lubricants leads to residues which remain on the surfaces of the component. Yan et al [35] investigated the influence of oil-and water-based cooling lubricants on the material properties of a Ti-6Al-4V component manufactured in a hybrid approach combining LMD and machining. In the case of material deposition on intermediate machined surfaces without an appropriate cleaning procedure, significant contamination and pronounced cracking were observed.…”

Section: Introductionmentioning

confidence: 99%

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Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Moritz

Seidel

Kopper

et al. 2020

Int J Adv Manuf Technol

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Hybrid manufacturing, which, e.g., combines additive manufacturing with conventional machining processes, can be a way of overcoming limitations currently encountered in additive manufacturing. Cryogenic milling might be a viable option for hard-tocut materials, as it leaves a contamination-free surface and can increase surface quality and tool life compared to conventional cooling concepts. In this study, the influence of cryogenic milling with carbon dioxide on titanium Ti-6Al-4V specimens manufactured with laser metal deposition (LMD) was investigated regarding tool wear and surface integrity in comparison to dry machining and machining with cooling lubricants. Moreover, additional layers of material were deposited on top of conventionally and cryogenically machined surfaces by means of LMD. The interface zone was then examined for defects. The milling process was closely monitored by means of thermal and high-speed imaging. Optical and tactile surface analysis provided evidence that lower roughness values and improved surface qualities could be obtained with cryogenic machining in comparison to dry machining. Moreover, significantly less tool wear was observed when a cryogenic cooling medium was applied. Although the utilization of conventional cooling lubricants resulted in satisfying surface qualities, substantial residual contamination on the milled surface was detected by means of fluorescence analysis. These contaminants are suspected to cause defects when the next layer of material is deposited. This is supported by the fact that pores were found in the weld bead applied on top of the milled specimens by means of LMD. Conversely, cryogenic machining resulted in very clean surfaces due to the residue-free evaporation of the coolant. Hence, a good metallurgical bonding between the weld bead and the milled substrate could be achieved. The results indicate the great potential of cryogenic milling in hybrid manufacturing, especially in terms of intermediate machining, as it provides residue-free surfaces for subsequent material deposition without an additional cleaning step and can significantly prolongate tool life.

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Section: Lmd On Machined Surfacesmentioning

confidence: 88%

Section: Introductionmentioning

confidence: 95%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Moritz

Seidel

Kopper

et al. 2020

Int J Adv Manuf Technol

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show abstract

“…Influence of the cutting fluids on the additive process . The remains of the cutting fluids from the machining process can influence the subsequent additive process [87]. This issue has a double effect.…”

Section: Study Of the Capabilities Of Hybrid Machinesmentioning

confidence: 99%

Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations

et al. 2018

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Hybrid machine tools combining additive and subtractive processes have arisen as a solution to increasing manufacture requirements, boosting the potentials of both technologies, while compensating and minimizing their limitations. Nevertheless, the idea of hybrid machines is relatively new and there is a notable lack of knowledge about the implications arisen from their in-practice use. Therefore, the main goal of the present paper is to fill the existing gap, giving an insight into the current advancements and pending tasks of hybrid machines both from an academic and industrial perspective. To that end, the technical-economical potentials and challenges emerging from their use are identified and critically discussed. In addition, the current situation and future perspectives of hybrid machines from the point of view of process planning, monitoring, and inspection are analyzed. On the one hand, it is found that hybrid machines enable a more efficient use of the resources available, as well as the production of previously unattainable complex parts. On the other hand, it is concluded that there are still some technological challenges derived from the interaction of additive and subtractive processes to be overcome (e.g., process planning, decision planning, use of cutting fluids, and need for a post-processing) before a full implantation of hybrid machines is fulfilled.

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“…Influence of the cutting fluids in the additive process. The remains of the cutting fluids from the machining process can influence the subsequent additive process[68]. This issue has a double effect.…”

mentioning

confidence: 99%

Latest Developments in Industrial Hybrid Machine Tools That Combine Additive and Subtractive Operations

Cortina¹,

Arrizubieta²,

Ruiz³

et al. 2018

Preprint

View full text Add to dashboard Cite

Hybrid machine tools combining additive and subtractive processes have arisen as a solution to the increasing manufacture requirements, boosting the potentials of both technologies, while compensating and minimizing their limitations. Nevertheless, the idea of hybrid machines is relatively new and there is a notable lack of knowledge in the field. Therefore, in the present paper, an insight into the advancements of hybrid machines is given, identifying their real capabilities, together with the latest developments from an industrial context. In addition, the current situation and future perspectives of hybrid machines from the point of view of process planning, monitoring and inspection are discussed. Finally, the challenges that must be overcome and the opportunities that the hybrid machines will provide in the forthcoming years are presented.

show abstract

Investigation of machining coolant residue cleaning methods for Ti6Al4V part fabrication through hybrid manufacturing process

Cited by 11 publications

References 10 publications

Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations

Latest Developments in Industrial Hybrid Machine Tools That Combine Additive and Subtractive Operations

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