Optical surface generation on additively manufactured AlSiMg0.75 alloys with ultrasonic vibration-assisted machining

Bai, Yuchao; Shi, Zhuoqi; Lee, Yan Jin; Wang, Hao

doi:10.1016/j.jmatprotec.2020.116597

Cited by 45 publications

(15 citation statements)

References 30 publications

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“…Researchers also explored the potential of non-conventional machining to produce an optical surface on additively manufactured parts. For example, a reflective surface with roughness as low as 5.1 nm is achieved by the combination of the optimized printing parameters and ultrasonic elliptical vibration-assisted machining in Ref [61]. By contrast, it is interesting to find that the conventional diamond turning can only obtain a surface roughness of 10.2 nm, as seen in Figure 17.…”

Section: Machining and Abrasive Finishingmentioning

confidence: 99%

“…These defects have serious influences on the internal microstructure and mechanics of the final parts [49][50][51][52][53][54][55]. Therefore, after the parts being manufactured, post-processing operations are usually required to improve the mechanical properties and the surface quality, achieving their intended utilization [56][57][58][59][60][61][62]. There have many post-processing technologies, such as the thermal post-processing method to release thermally-induced residual stress and laser peening to reduce micro-defects and improve surface quality.…”

Section: Introductionmentioning

confidence: 99%

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A Review of Post-Processing Technologies in Additive Manufacturing

Peng

Kong

Fuh

et al. 2021

JMMP

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Additive manufacturing (AM) technology has rapidly evolved with research advances related to AM processes, materials, and designs. The advantages of AM over conventional techniques include an augmented capability to produce parts with complex geometries, operational flexibility, and reduced production time. However, AM processes also face critical issues, such as poor surface quality and inadequate mechanical properties. Therefore, several post-processing technologies are applied to improve the surface quality of the additively manufactured parts. This work aims to document post-processing technologies and their applications concerning different AM processes. Various types of post-process treatments are reviewed and their integrations with AM process are discussed.

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Section: Machining and Abrasive Finishingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Review of Post-Processing Technologies in Additive Manufacturing

Peng

Kong

Fuh

et al. 2021

JMMP

Self Cite

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“…Tay and Haider 14 were able to improve surface roughness of AM components using electroless nickel plating without affecting the dimensional accuracy. In the work of Bai et al 15 a series of postprocessing analyses have been conducted to optimise the SLM fabricated samples to achieve improved material properties and machinability for additively manufactured metal alloys. Kaynak and Kitay 16 recommended the use of drag finishing and vibratory surface finishing techniques for post-processing AM-fabricated parts.…”

Section: Introductionmentioning

confidence: 99%

Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

Kashouty

Rennie

Ghazy

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Manufacturing process constraints and design complexities are the main challenges that face the aftermarket automotive industry. For that reason, recently, selective laser melting (SLM) is being recognised as a viable approach in the fabrication of injection moulding tool inserts. Due to its versatility, SLM technology is capable of producing freeform designs. For the first reported time, in this study SLM is recognized for its novel application in overcoming fabrication complexities for prism shaped topology of a vehicle headlamp’s reflector injection moulding tool insert. Henceforth, performance measures of the SLM-fabricated injection mould tool insert is assessed in comparison to a CNC-milled counterpart to improve quality characteristics. Tests executed and detailed in this paper are divided into two stages; the first stage assesses both fabricated tool inserts in terms of manufacturability; the second stage assesses the functionality of the end-products by measuring the surface roughness, dimensional accuracy and light reflectivity from the vehicle reflectors. The results obtained show that employing SLM technology can offer an effective and efficient alternative to subtractive manufacturing, successfully producing tool inserts with complex surface topology. Significant benefits in terms of surface roughness, dimensional accuracy and product functionality were achieved through the use of SLM technology. it was concluded that the SLM-fabricated inserts products proved to have relatively lower values of surface roughness in comparison to their CNC counterparts.

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“…Further, material removal ratio for UVC was near to unity indicating reduction on plowing effect by ultrasonic vibration unlike CT. Recently, ultrasonic elliptical vibration assisted machining (UEVAM) was used for the postprocessing of additive manufactured AISiMg 0.75 to generate optical surface finish [30]. UEVAM was proven to be efficient by reducing cutting forces and generating superior surface finish replacing two-step postprocessing route of heat treatment followed by conventional diamond turning.…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic vibration-assisted turning of Titanium alloy Ti–6Al–4V: numerical and experimental investigations

Kandi

Sahoo

2020

J Braz. Soc. Mech. Sci. Eng.

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The machining of Titanium alloy, Ti-6Al-4V has got an extensive attention from industries like aerospace, medical, and biomedical plants due its unique properties like high strength at elevated temperature and better strength to weight ratio. Still, properties like reduced thermal conductivity, affinity to react with the tool and work hardening make difficult to cut it by conventional turning process. Ultrasonic vibration-assisted turning (UVAT) is one of the advanced turning method in which tool is allowed to vibrate with ultrasonic frequency (~ 20 kHz) with small amplitude and hence converting the continuous cutting to an intermittent cutting process. In the present work a horn (acts as an amplifier as well as a tool holder) with inserted tool tip is designed and FEM analysis has been done for its suitability for the process. The dynamic analysis has also been performed to find out the stress distribution in both parts under cyclic loading conditions. It enables to locate the highly stressed nodal regions. Experimental investigation has been carried out for both conventional turning (CT) and UVAT processes to demonstrate effects of various inputs on the output responses like cutting forces, surface roughness, tool wear and temperature rise in UVAT. Additionally, a 3D finite element model for UVAT and CT has been prepared. The simulation results like force and steady state tool tip temperature have also been validated with the experimental results and found to be in good agreement. The advantages of UVAT process have been discovered in terms of reduction in the cutting forces and surface roughness for the used Ti-6Al-4V workpiece.

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Optical surface generation on additively manufactured AlSiMg0.75 alloys with ultrasonic vibration-assisted machining

Cited by 45 publications

References 30 publications

A Review of Post-Processing Technologies in Additive Manufacturing

A Review of Post-Processing Technologies in Additive Manufacturing

Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

Ultrasonic vibration-assisted turning of Titanium alloy Ti–6Al–4V: numerical and experimental investigations

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