Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

Struzikiewicz, Grzegorz; Sioma, Andrzej

doi:10.3390/ma15103604

Cited by 5 publications

(2 citation statements)

References 43 publications

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“…When milling surfaces after metallic 3D (three-dimensional) printing, material cracks may remain on the surface after processing. In [ 18 ], the test results showed the presence of cracks and breaches on the milled surface. It was shown that the depth and size of the cracks depend on the cutting edge feed and the milling method.…”

Section: Introductionmentioning

confidence: 99%

Comparative Study of the Dimensional and Shape Accuracy of Parts Made of 316L Manufactured Using the SLM and Casting Methods after Milling and WEDM

Machno,

Zębala

2024

Materials

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Parts made using selective laser melting (SLM) often require improvements to the quality of side surfaces. Therefore, the analysis of the machinability of metallic printed material is new/innovative. The surface of printed parts requires improvement in quality—surface roughness. Hence, there is a need for effective manufacturing techniques that improve the quality of the side surfaces of printed parts. In our work, we try to fill this research gap. This work comparatively analyzed the surface quality (roughness parameter Ra) after milling and wire electrical discharge machining (WEDM). The processed material was AISI 316L stainless steel, which was produced using the casting and SLM method. In the case of printed material, the influence of the direction of the tool (perpendicular, parallel) on the arrangement of sintered layers was also analyzed. The analysis of the results showed that processing the cast material and processing the material perpendicular to the arrangement of the layers gives similar results—similar relationships between the processing parameters and surface roughness were observed. However, processing parallel to the arrangement of sintered layers showed ambiguity in the relationships. Moreover, the best results of the Ra parameter (0.1–0.2 µm) were obtained for feeds of 0.08 mm/rev and 0.12 mm/rev and a cutting speed of 90 m/min. In this work, the novelty is the comparison of the surfaces of materials manufactured using different techniques (SLM, casting) after milling and WEDM processing.

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Section: Introductionmentioning

confidence: 99%

Comparative Study of the Dimensional and Shape Accuracy of Parts Made of 316L Manufactured Using the SLM and Casting Methods after Milling and WEDM

Machno,

Zębala

2024

Materials

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“…For example, measurements of the parameters of the geometrical structure of the surface in terms of surface defects and surface roughness require an individual approach, which must consider the type of material and the conditions for the measurement. For example, measurements of the parameters of materials produced by selective laser sintering required the selection of the kind of lighting and a specialized optical path for the imaging method [7]. The choice of the type of illuminator is a crucial task from the point of view of industrial imaging.…”

Section: Introductionmentioning

confidence: 99%

Modelling the Interaction of Illuminations with a Sensor Matrix Used in Vision Systems

Waśniowska,

Sioma

2023

Applied Sciences

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The article discusses a method of modelling the interaction of industrial illuminators with sensor arrays used in industrial vision systems cameras. The research used a model containing a light source and a sensor matrix. As part of the research, the average intensity of electromagnetic radiation in the visible range on the surface of the sensor matrix was measured, as well as its analysis and interpretation using a model of illuminators. The light source is described based on the measurement of an authentic industrial illuminator, for which a photometric solid was determined using a photogoniometer and spectral irradiance with a spectroradiometer. A theoretical model of the matrix was prepared, enabling the selection and control of the parameters of its work. As part of the conducted research, the impact of changing the lighting model parameters, such as the photometric solid, spectral irradiance, and number of rays, and the effect of changing the matrix parameters, such as the dimensions, number of pixels, on the irradiance measurement, were checked. The results of simulation tests are presented for selected sets of models of the light source and for the model of sensors’ matrix. The summary presents the impact of changes in parameters adopted for models on the simulation results.

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Review of improvement of machinability and surface integrity in machining on aluminum alloys

Pimenov,

Kiran,

Khanna

et al. 2023

Int J Adv Manuf Technol

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Aluminum alloys are widely used in many industries, including aerospace, automotive, civil, and electrical engineering. When compared to pure aluminum, most aluminum alloys have lower electrical and thermal conductivity, corrosion resistance, and weldability, as well as a low density and specific gravity. At the same time, the properties of aluminum alloys vary significantly depending on the group, which has a significant impact on their machinability. This review article is focused on the study of machining characteristics of aluminum alloys, such as machinability, surface integrity, tool wear and tool life, material removal rate (MRR), and chip morphology. The directions of increasing machinability by controlling cutting parameters, cutting environment, such as dry machining, conventional cooling systems, minimum quantity of lubricant (MQL), cryogenic lubrication (CL), with tool geometry, and textured tools, are also considered; tool materials include coating, vibration, thermally, and hybrid assisted machining. The article discusses the main types of machining, namely, turning, milling, drilling, and grinding. It shows ways to increase the machinability of machining on aluminum alloys, as well as the advantages and disadvantages. From the literature, it can be concluded that tool wear when machining aluminum alloys is 30–40% lower than when machining steel alloys due to their higher ductility and lower strength. Surface integrity, affected by the cutting parameters and cutting temperatures — which can reach between 200 and 400 °C — can vary by up to 15% in hardness and 20% in surface roughness. Cutting tool characteristics can enhance surface finish by up to 25% and extend tool life, reducing edge formation by up to 30%. Chip morphology, influenced by factors such as cutting parameters and tool material, can improve tool life by up to 35%. Vibration techniques can reduce thermal effects and improve surface finish by up to 40%, reducing cutting forces by around 30%.

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Surface Topographic Features after Milling of Additively Manufactured AlSi10Mg Aluminum Alloy

Cited by 5 publications

References 43 publications

Comparative Study of the Dimensional and Shape Accuracy of Parts Made of 316L Manufactured Using the SLM and Casting Methods after Milling and WEDM

Comparative Study of the Dimensional and Shape Accuracy of Parts Made of 316L Manufactured Using the SLM and Casting Methods after Milling and WEDM

Modelling the Interaction of Illuminations with a Sensor Matrix Used in Vision Systems

Review of improvement of machinability and surface integrity in machining on aluminum alloys

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