Finish Machining of Additive Manufactured Metals

增材制造金属的精加工

• 批准号: RGPIN-2020-06162
• 负责人: Hosseini, SayyedAli
• 金额: $ 1.97万
• 依托单位: University of Ontario Institute of Technology
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2020
• 资助国家: 加拿大
• 起止时间: 2020-01-01 至 2021-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=717961
• 关键词: Finish; Machining; Additive; Manufactured; Metals

Additive manufacturing (AM) creates geometries by depositing/spreading material layer-by-layer wherever desired and was historically used as a convenient method to make prototypes for demonstration or pre-use assessment. Significant progress in technology and equipment has resulted in an awareness of the capabilities of AM for producing highly customized parts for service applications. Hence, there has recently been a surge in the number of research projects exploring the capabilities and potential applications of AM. This trend also encouraged the manufacturing industry to explore metals, rather than easy to deposit materials such as plastics. However, one of the major roadblocks toward the wide application of AM metallic parts goes back to their inherent layer-by-layer nature where each layer is deposited and solidified over the previous layer. Other issues with AM parts are poor surface quality and lack of dimensional accuracy, which are critical factors for many applications. Therefore, post processing the AM parts is an inevitable step toward preparing them for their service life. Post processing AM parts to attain the desired tolerances is mainly achieved using finish machining. Successful machining highly depends on the characteristics of material to be machined. Machining also alters the surface and subsurface characteristics, which needs thorough investigation. The proposed NSERC DG program specifically focuses on three interconnected areas: Studying the effect of AM on the mechanical behavior of AM metals Developing a constitutive equation and a force model for machining AM metals to predict the cutting forces based on the mechanical properties of AM metals Investigating the attainable surface integrity after finish machining of AM metals Process of choice will be metal powder bed fusion (laser beam), as a widely used AM technique. Materials of focus will be titanium alloys and superalloys (nickel-based) that are widely used in aerospace industry and are more likely candidates for AM, due to their difficult-to-cut nature. The proposed research will enable the manufacturing industry to have a better understanding of the expected material behavior during the post-process finish machining of metallic parts after AM. It will also enable training of students in key areas pertaining to both machining and additive manufacturing. The exclusive targets of this research make the proposed program particularly unique and specialized due to the fact that, to the best of my knowledge, there has not yet been extensive research pertaining to the post-process finish machining of AM metallic parts. This research will certainly lead to future progress, particularly, concerning the quality, integrity, and overall performance of the AM metals that undergo post-process finish machining. The manufacturing sector serves as one of the main driving forces for Canada's economy; hence, the proposed research holds great promise for the Canadian economy.

增材制造（AM）通过在任何需要的地方逐层沉积/扩散材料来创建几何形状，并且历来被用作制作演示或使用前评估原型的方便方法。技术和设备的重大进步使人们意识到增材制造能够为服务应用生产高度定制的零件。因此，最近探索增材制造的能力和潜在应用的研究项目数量激增。这种趋势也鼓励制造业探索金属，而不是容易沉积的材料，如塑料。然而，AM金属部件广泛应用的主要障碍之一是其固有的逐层性质，每一层都是在前一层之上沉积和固化的。增材制造零件的其他问题是表面质量差和缺乏尺寸精度，这是许多应用的关键因素。因此，后处理AM零件是为其使用寿命做准备的不可避免的一步。后处理增材制造零件以获得所需的公差主要是通过精加工实现的。成功的加工在很大程度上取决于被加工材料的特性。加工也会改变表面和亚表面特性，这需要深入研究。