Use of energy consumption during milling to fill a measurement gap in hybrid additive manufacturing
Use of energy consumption during milling to fill a measurement gap in hybrid additive manufacturing
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DOI：
10.1016/j.addma.2021.102167
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发表时间：
2021-10
影响因子：
11
通讯作者：
K. Avegnon;P. Noll;M. Uddin;G. Madireddy;Robert E. Williams;A. Achuthan;M. Sealy
中科院分区：
文献类型：
--
作者：
K. Avegnon;P. Noll;M. Uddin;G. Madireddy;Robert E. Williams;A. Achuthan;M. Sealy
将增材制造（AM）与层间喷丸结合在几厘米的构造内引入了体各向异性特性。目前绘制高分辨率各向异性和非均质性的方法要么是破坏性的，要么使用非破坏性方法具有有限的穿透深度。绘制高分辨率各向异性和非均质性的替代伪非破坏性方法是通过研磨期间的能量消耗。先前的研究表明，铣削过程中的能耗与表面完整性相关。由于增材制造零件的表面铣削通常需要进行后处理以提高尺寸精度，因此有机会使用表面铣削作为测量机械性能和构建质量的替代方法。增材零件以及混合增材零件加工过程中的能耗变化知之甚少。在这项研究中，使用净切割比能被提出作为一个合适的度量测量层间超声喷丸后的316不锈钢的机械性能。能源消耗被映射到整个立方体构建体积的一半。结果表明，净切割比能的变化增加进一步远离表面，是更高的混合AM相比，印刷和锻造。印刷样品的净切割比能的平均横向和层间变化比对照高81%，这表明了显着更高程度的异质性。此外，还发现，能量消耗是一个有效的过程签名表现出强烈的相关性与显微硬度。基于残余应变的各向异性用净切削比能测量，并通过钻孔验证。所提出的技术有助于填补混合增材制造中的部分测量空白，并利用预先存在的AM零件加工需求，在一次铣削操作中实现表面光洁度和质量评估的目标。
Coupling additive manufacturing (AM) with interlayer peening introduces bulk anisotropic properties within a build across several centimeters. Current methods to map high resolution anisotropy and heterogeneity are either destructive or have a limited penetration depth using a non-destructive method. An alternative pseudo-nondestructive method to map high resolution anisotropy and heterogeneity is through energy consumption during milling. Previous research has shown energy consumption during milling correlates with surface integrity. Since surface milling of additively manufactured parts is often required for post-processing to improve dimensional accuracy, an opportunity is available to use surface milling as an alternative method to measure mechanical properties and build quality. The variation of energy consumption during the machining of additive parts, as well as hybrid AM parts, is poorly understood. In this study, the use of net cutting specific energy was proposed as a suitable metric for measuring mechanical properties after interlayer ultrasonic peening of 316 stainless steel. Energy consumption was mapped throughout half of a cuboidal build volume. Results indicated the variation of net cutting specific energy increased further away from the surface and was higher for hybrid AM compared to as-printed and wrought. The average lateral and layer variation of the net cutting specific energy for printed samples was 81% higher than the control, which indicated a significantly higher degree of heterogeneity. Further, it was found that energy consumption was an effective process signature exhibiting strong correlations with microhardness. Anisotropy based on residual strains were measured using net cutting specific energy and validated by hole drilling. The proposed technique contributes to filling part of the measure gap in hybrid additive manufacturing and capitalizes on the pre-existing need for machining of AM parts to achieve both goals of surface finish and quality assessment in one milling operation.