A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns
A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns
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DOI：
10.3390/app11209428
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发表时间：
2021-10
期刊：
影响因子：
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通讯作者：
M. M. Parvez-M.;Sahil Patel;S. P. Isanaka;F. Liou
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文献类型：
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作者：
M. M. Parvez-M.;Sahil Patel;S. P. Isanaka;F. Liou
在增材制造（AM）中，沉积部件的表面粗糙度仍然显著高于大多数应用的容许范围。此外，AM部件的表面形貌在轨道和层之间表现出波纹轮廓。因此，后处理对于提高表面质量必不可少。激光辅助加工和抛光可以是有效的表面改善工艺，由于它们作为许多金属AM工艺中的主要能源的可用性，因此可以使用它们。虽然大多数AM部件的表面的初始粗糙度和波纹度非常高，但为了实现尺寸精度并使粗糙度最小化，在机加工和抛光工艺期间需要高输入能量密度，尽管这种高能量密度可能引起工艺缺陷并使波长粗糙现象升级。在本文中，我们提出了一个系统的方法来消除波纹和减少表面粗糙度的激光辅助加工，宏观抛光和微观抛光工艺相结合。虽然机械加工降低了初始波纹度，但抛光过程中的低能量密度可以进一步降低初始波纹度。在本研究中，使用优化的加工和抛光工艺参数获得的平均粗糙度（Ra=1.11μm）表明，与完工部件相比，粗糙度降低了97%以上。
In additive manufacturing (AM), the surface roughness of the deposited parts remains significantly higher than the admissible range for most applications. Additionally, the surface topography of AM parts exhibits waviness profiles between tracks and layers. Therefore, post-processing is indispensable to improve surface quality. Laser-aided machining and polishing can be effective surface improvement processes that can be used due to their availability as the primary energy sources in many metal AM processes. While the initial roughness and waviness of the surface of most AM parts are very high, to achieve dimensional accuracy and minimize roughness, a high input energy density is required during machining and polishing processes although such high energy density may induce process defects and escalate the phenomenon of wavelength asperities. In this paper, we propose a systematic approach to eliminate waviness and reduce surface roughness with the combination of laser-aided machining, macro-polishing, and micro-polishing processes. While machining reduces the initial waviness, low energy density during polishing can minimize this further. The average roughness (Ra=1.11μm) achieved in this study with optimized process parameters for both machining and polishing demonstrates a greater than 97% reduction in roughness when compared to the as-built part.