Machinability of wire and arc additive manufactured components
Machinability of wire and arc additive manufactured components
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DOI：
10.1016/j.cirpj.2021.06.022
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发表时间：
2021-07-24
影响因子：
4.8
通讯作者：
Van Rymenant, Patrick
中科院分区：
文献类型：
--
作者：
Chernovol, Nataliia;Sharma, Abhay;Van Rymenant, Patrick
线弧增材制造（WAAM）旨在成为一种具有成本效益和材料效率的工艺，以生产中型和大型金属零件。然而，由于沉积表面的低质量，仍然需要后处理。为了揭示焊接和加工现象之间的复杂相互作用，这决定了最终的表面质量，本文通过对加法和减法工艺的关键参数进行全面调查，重点研究了WAAM零件的可加工性。WAAM参数对沉积零件特性的影响（即，硬度、平面度偏差、壁厚和初始表面波纹度）和加工工艺进行了分析。因此，首次提出了一种非线性函数，可以预测焊接和铣削参数对最终表面粗糙度的影响。当地（例如，表面不规则性和硬度）和全局（例如，壁厚）对焊接热输入的影响以及由此产生的对加工稳定性的影响。例如，缓慢的焊接速度导致不容易加工的柔软且不规则的表面。然而，与此同时，低速增加了壁宽，这提供了必要的阻尼，以减少加工期间的颤振。所得结果有助于理解WAAM和铣削过程之间的相互作用，并进一步确定最佳加工余量和最佳工艺条件。(C)2021 CIRP。
Wire and Arc Additive Manufacturing (WAAM) aims to be a cost-effective and material-efficient process to produce medium and large-scale metal parts. Nevertheless, post-processing is still required due to the low quality of the as-deposited surface. With the objective to divulge the complex interaction between the welding and machining phenomena, which determines the final surface quality, this paper focuses on the machinability of WAAM parts through a comprehensive investigation on the key parameters of both additive and subtractive processes. The effect of the WAAM parameters on the as-deposited part characteristics (i.e., hardness, flatness deviation, wall thickness, and initial surface waviness) and machining process has been analyzed. Consequently, the first of its kind, a non-linear function that can predict the effect of welding and milling parameters on the final surface roughness, is presented. The complex interaction between the local (e.g., surface irregularities and hardness) and global (e.g., wall thickness) effects of welding heat input and the resulting impact on the machining stability is analyzed. For example, slow welding speed results in a soft and irregular surface that is not easy to machine. Still, at the same time, the slow speed increases the wall width that provides the essential damping to reduce the chatter during machining. The obtained results help understand the interactions between the WAAM and milling processes and further determine the optimal machining allowances and optimal process conditions. (C) 2021 CIRP.