Synergistic effects in hydrodynamic cavitation abrasive finishing for internal surface-finish enhancement of additive-manufactured components

Nagalingam, Arun Prasanth; Yuvaraj, Hemanth Kumar; Yeo, Song Huat

doi:10.1016/j.addma.2020.101110

Cited by 50 publications

(31 citation statements)

References 61 publications

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“…A totally polished surface can indeed drastically reduce the bacterial adhesion and proliferation but, at the same time, hinder the cell attachment and colonization of the implant. One of the disadvantages of the additive manufacturing (AM) technologies over the conventional techniques is the requirement of post-processing operations due to the inadequate dimensional accuracy and surface finishing that result from a layer-by-layer deposition of material [30][31][32][33]. Moreover, the advantages of the lead time reduction offered by 3D printing are often affected by the time-consuming techniques, including manual operations for curved or complex geometries, required to modify the surface quality of as-build samples.…”

Section: Introductionmentioning

confidence: 99%

Selective Laser Melting and Electron Beam Melting of Ti6Al4V for Orthopedic Applications: A Comparative Study on the Applied Building Direction

et al. 2020

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The 3D printing process offers several advantages to the medical industry by producing complex and bespoke devices that accurately reproduce customized patient geometries. Despite the recent developments that strongly enhanced the dominance of additive manufacturing (AM) techniques over conventional methods, processes need to be continually optimized and controlled to obtain implants that can fulfill all the requirements of the surgical procedure and the anatomical district of interest. The best outcomes of an implant derive from optimal compromise and balance between a good interaction with the surrounding tissue through cell attachment and reduced inflammatory response mainly caused by a weak interface with the native tissue or bacteria colonization of the implant surface. For these reasons, the chemical, morphological, and mechanical properties of a device need to be designed in order to assure the best performances considering the in vivo environment components. In particular, complex 3D geometries can be produced with high dimensional accuracy but inadequate surface properties due to the layer manufacturing process that always entails the use of post-processing techniques to improve the surface quality, increasing the lead times of the whole process despite the reduction of the supply chain. The goal of this work was to provide a comparison between Ti6Al4V samples fabricated by selective laser melting (SLM) and electron beam melting (EBM) with different building directions in relation to the building plate. The results highlighted the influence of the process technique on osteoblast attachment and mineralization compared with the building orientation that showed a limited effect in promoting a proper osseointegration over a long-term period.

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Section: Introductionmentioning

confidence: 99%

Selective Laser Melting and Electron Beam Melting of Ti6Al4V for Orthopedic Applications: A Comparative Study on the Applied Building Direction

et al. 2020

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“…were observed in MJ-HCAF of PBF-LB/Alloy 625 using an abrasive concentration of ≤1% weight with a processing time of up to 15 min, [190].…”

Section: Non-conventional Abrasive Fine Finishingmentioning

confidence: 89%

“…HCAF upgrades UCAF by closing the hydrodynamic loop, i.e., realizing a closed upstream and downstream hydrodynamic cavitation stream. Similar to UCAF, the material removal mechanism in HCAF consists of 1) erosion due to implosion of the cavitation bubbles (pure cavitation), 2) pure microparticle abrasion, and 3) cavitation-assisted microparticle abrasion [190], as shown in Fig. 19.…”

Section: Non-conventional Abrasive Fine Finishingmentioning

confidence: 99%

Post-processing of additively manufactured metallic alloys – A review

Malakizadi

Mallipeddi

Dadbakhsh

et al. 2022

International Journal of Machine Tools and Manufacture

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“…The synergistic effects resulting from the interaction between added micro-particles and the bubbles further enhances the finishing capability. 9 This technique led to 90% surface texture improvement of AlSi10Mg with initial surface roughness of R a $20 mm in 150 minutes (Nagalingam et al 12 ).…”

Section: Introductionmentioning

confidence: 99%

Experimental evaluation of electrophoretic deposition-assisted polishing

Adibi

Khani

Esmaeili

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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The quest for precision in manufacturing sector is continuously evolving with the introduction of modern technologies and new techniques. In this research, the characteristics and influential parameters of a recently developed polishing process, known as electrophoretic deposition-assisted polishing (EPDAP), were investigated in external surface polishing of AISI 316 L stainless steel. The results revealed the improvement of surface roughness with increasing axial load up to the certain value of 11 N. The polishing time between 6 min and 12 min was recommended for polishing surfaces having a moderate initial roughness, close to 0.1 µm. Moreover, the increase of tool rotational speed led to the improvement of surface quality, while the variation of applied voltage had insignificant effects on the surface texture. In the second series of experiments, predictive equations of average surface roughness and material removal rate (MRR) were obtained based on analysis of variance. It was concluded that axial load and tool rotational speed are the most influential parameters on surface roughness and MRR, respectively. By performing a multi-response optimization, the optimum levels of control parameters at the same voltage of 15 V were calculated as axial load of 12 N, polishing time of 10 min, and tool rotational speed of 2000 rpm. This combination reduced the average surface roughness by 54.17% relative to the worst condition, which is characterized by the lowest axial loads, rotational speed, and polishing time at the design space. The maximum MRR of 3.975 mg/min was achieved at this optimum point. Assessment of the surface features indicated that the EPDAP process created uniform roughness profiles and resulted in an enhanced surface reflectance.

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Synergistic effects in hydrodynamic cavitation abrasive finishing for internal surface-finish enhancement of additive-manufactured components

Cited by 50 publications

References 61 publications

Selective Laser Melting and Electron Beam Melting of Ti6Al4V for Orthopedic Applications: A Comparative Study on the Applied Building Direction

Selective Laser Melting and Electron Beam Melting of Ti6Al4V for Orthopedic Applications: A Comparative Study on the Applied Building Direction

Post-processing of additively manufactured metallic alloys – A review

Experimental evaluation of electrophoretic deposition-assisted polishing

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