Effects of Milling Process Parameters on Cutting Forces and Surface Roughness When Finishing Ti6al4v Produced by Electron Beam Melting
Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology, which uses computer-controlled electron beams to create fully dense three-dimensional near-net-shaped parts from metal powder. It gives the ability to produce any complex parts directly from a computer-aided design (CAD) model without tools and dies, and with a variety of materials. However, the quality of the surface finish in EBM process has limitations to meeting the performance requirements of additively manufactured components. The aim of this study is to investigate the cutting forces induced during milling Ti6Al4V produced by EBM as well as the surface quality of the milled surfaces. The effects of cutting speed and radial depth of cut on the cutting forces, surface roughness, and surface morphology were investigated. The results indicated that the cutting speed was found to be proportional to the resultant cutting force at any cutting conditions while the surface roughness improved significantly with the increase in cutting speed and radial depth of cut.
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[2] P. Reeves, "ATKINS: manufacturing a low carbon footprint: zero emission enterprise feasability study," in 2nd International Conference on Additive Technologies (iCAT), 2008, pp. 17-19.
[3] C. Garcia, R. Rumpf, H. Tsang, and J. Barton, "Effects of extreme surface roughness on 3D printed horn antenna," Electronics Letters, vol. 49, no. 12, pp. 734-736, 2013.
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[7] K. Salonitis, L. D’Alvise, B. Schoinochoritis, and D. Chantzis, "Additive manufacturing and post-processing simulation: laser cladding followed by high speed machining," The International Journal of Advanced Manufacturing Technology, vol. 85, no. 9-12, pp. 2401-2411, 2016.
[8] S. Singh, S. Ramakrishna, and R. Singh, "Material issues in additive manufacturing: A review," Journal of Manufacturing Processes, vol. 25, pp. 185-200, 2017.
[9] J. Giannatsis and V. Dedoussis, "Additive fabrication technologies applied to medicine and health care: a review," The International Journal of Advanced Manufacturing Technology, vol. 40, no. 1-2, pp. 116-127, 2009.
[10] N. Saengchairat, T. Tran, and C.-K. Chua, "A review: Additive manufacturing for active electronic components," Virtual and Physical Prototyping, vol. 12, no. 1, pp. 31-46, 2017.
[11] R. Huang et al., "Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components," Journal of Cleaner Production, vol. 135, pp. 1559-1570, 2016.
[12] R. Hague*, S. Mansour, and N. Saleh, "Material and design considerations for rapid manufacturing," International Journal of Production Research, vol. 42, no. 22, pp. 4691-4708, 2004.
[13] A. Boschetto, L. Bottini, and F. Veniali, "Surface roughness and radiusing of Ti6Al4V selective laser melting-manufactured parts conditioned by barrel finishing," The International Journal of Advanced Manufacturing Technology, vol. 94, no. 5-8, pp. 2773-2790, 2018.
[14] A. Iquebal, S. Shrestha, Z. Wang, G. Manogharan, S. Bukkapatnam, and O. Youngstown, "Influence of Milling and Non-Traditional Machining on Surface Properties of Ti6Al4V EBM Components," in Proceedings of the 2016 Industrial and Systems Engineering Research Conference, 2016.
[15] J.-P. Kruth, M. Badrossamay, E. Yasa, J. Deckers, L. Thijs, and J. Van Humbeeck, "Part and material properties in selective laser melting of metals," in Proceedings of the 16th international symposium on electromachining, 2010.
[16] E. Yasa and J.-P. Kruth, "Application of laser re-melting on selective laser melting parts," Advances in Production engineering and Management, vol. 6, no. 4, pp. 259-270, 2011.
[17] A. Lamikiz, J. Sanchez, L. L. de Lacalle, and J. Arana, "Laser polishing of parts built up by selective laser sintering," International Journal of Machine Tools and Manufacture, vol. 47, no. 12-13, pp. 2040-2050, 2007.
[18] B. Rosa, P. Mognol, and J.-Y. Hascoët, "Laser polishing of additive laser manufacturing surfaces," Journal of Laser Applications, vol. 27, no. S2, p. S29102, 2015.
[19] D. Bhaduri, P. Penchev, S. Dimov, and S. Soo, "Improving the surface integrity of 3D printed stainless steel parts by laser polishing'," Proceedings of the M, vol. 4, pp. 593-596, 2015.
[20] I. Mingareev et al., "Femtosecond laser post-processing of metal parts produced by laser additive manufacturing," Journal of Laser Applications, vol. 25, no. 5, p. 052009, 2013.
[21] S. Marimuthu, A. Triantaphyllou, M. Antar, D. Wimpenny, H. Morton, and M. Beard, "Laser polishing of selective laser melted components," International Journal of Machine Tools and Manufacture, vol. 95, pp. 97-104, 2015.
[22] T. L. Perry, D. Werschmoeller, X. Li, F. E. Pfefferkorn, and N. A. Duffie, "Pulsed laser polishing of micro-milled Ti6Al4V samples," Journal of Manufacturing Processes, vol. 11, no. 2, pp. 74-81, 2009.
[23] B. Rosa, J.-Y. Hascoët, and P. Mognol, "Topography modeling of laser polishing on AISI 316L milled surfaces," Mechanics & industry, vol. 15, no. 1, pp. 51-61, 2014.
[24] S. Bagehorn, T. Mertens, D. Greitemeier, L. Carton, and A. Schoberth, "Surface finishing of additive man-ufactured ti-6al-4v–a comparison of electrochemical and mechanical treatments," in 6th Eur conf aerosp sci, 2015.
[25] A. Dolimont et al., "Influence on surface characteristics of electron beam melting process (EBM) by varying the process parameters," in AIP Conference Proceedings, 2017, vol. 1896, no. 1: AIP Publishing, p. 040010.
[26] S. Bagehorn, J. Wehr, and H. Maier, "Application of mechanical surface finishing processes for roughness reduction and fatigue improvement of additively manufactured Ti-6Al-4V parts," International Journal of Fatigue, vol. 102, pp. 135-142, 2017.
[27] F. Calignano, D. Manfredi, E. Ambrosio, L. Iuliano, and P. Fino, "Influence of process parameters on surface roughness of aluminum parts produced by DMLS," The International Journal of Advanced Manufacturing Technology, vol. 67, no. 9-12, pp. 2743-2751, 2013.
[28] B. AlMangour and J.-M. Yang, "Improving the surface quality and mechanical properties by shot-peening of 17-4 stainless steel fabricated by additive manufacturing," Materials & Design, vol. 110, pp. 914-924, 2016.
[29] A. B. Spierings, N. Herres, and G. Levy, "Influence of the particle size distribution on surface quality and mechanical properties in AM steel parts," Rapid Prototyping Journal, vol. 17, no. 3, pp. 195-202, 2011.
[30] I. V. Arasu and K. Chockalingam, "Impact of post processing parameter on mechanical properties and surface roughness of selective laser sintered sand mold casting part," 2018.
[31] A. Safdar, H. He, L.-Y. Wei, A. Snis, and L. E. Chavez de Paz, "Effect of process parameters settings and thickness on surface roughness of EBM produced Ti-6Al-4V," Rapid Prototyping Journal, vol. 18, no. 5, pp. 401-408, 2012.
[32] D. Greitemeier, C. Dalle Donne, F. Syassen, J. Eufinger, and T. Melz, "Effect of surface roughness on fatigue performance of additive manufactured Ti–6Al–4V," Materials Science and Technology, vol. 32, no. 7, pp. 629-634, 2016.
[33] H. Masuo et al., "Effects of Defects, Surface Roughness and HIP on Fatigue Strength of Ti-6Al-4V manufactured by Additive Manufacturing," Procedia Structural Integrity, vol. 7, pp. 19-26, 2017.
[34] P. Oxley, "Mechanics of Manchining, An Analytical Approach to Assessing Machinability. Halsted Press," New York, 1989.
[35] A. Daymi, M. Boujelbene, S. B. Salem, B. H. Sassi, and S. Torbaty, "Effect of the cutting speed on the chip morphology and the cutting forces," Archives of Computational Materials Science and Surface Engineering, vol. 1, no. 2, pp. 77-83, 2009.
[1] I. Gibson, D. Rosen, and B. Stucker, "others, Additive manufacturing technologies," ed: Springer, 2010.
[2] P. Reeves, "ATKINS: manufacturing a low carbon footprint: zero emission enterprise feasability study," in 2nd International Conference on Additive Technologies (iCAT), 2008, pp. 17-19.
[3] C. Garcia, R. Rumpf, H. Tsang, and J. Barton, "Effects of extreme surface roughness on 3D printed horn antenna," Electronics Letters, vol. 49, no. 12, pp. 734-736, 2013.
[4] A. Townsend, N. Senin, L. Blunt, R. Leach, and J. Taylor, "Surface texture metrology for metal additive manufacturing: a review," Precision Engineering, vol. 46, pp. 34-47, 2016.
[5] I. Gibson, D. W. Rosen, and B. Stucker, "Additive manufacturing technologies. 2010," Google Scholar.
[6] W. J. Sames, F. List, S. Pannala, R. R. Dehoff, and S. S. Babu, "The metallurgy and processing science of metal additive manufacturing," International Materials Reviews, vol. 61, no. 5, pp. 315-360, 2016.
[7] K. Salonitis, L. D’Alvise, B. Schoinochoritis, and D. Chantzis, "Additive manufacturing and post-processing simulation: laser cladding followed by high speed machining," The International Journal of Advanced Manufacturing Technology, vol. 85, no. 9-12, pp. 2401-2411, 2016.
[8] S. Singh, S. Ramakrishna, and R. Singh, "Material issues in additive manufacturing: A review," Journal of Manufacturing Processes, vol. 25, pp. 185-200, 2017.
[9] J. Giannatsis and V. Dedoussis, "Additive fabrication technologies applied to medicine and health care: a review," The International Journal of Advanced Manufacturing Technology, vol. 40, no. 1-2, pp. 116-127, 2009.
[10] N. Saengchairat, T. Tran, and C.-K. Chua, "A review: Additive manufacturing for active electronic components," Virtual and Physical Prototyping, vol. 12, no. 1, pp. 31-46, 2017.
[11] R. Huang et al., "Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components," Journal of Cleaner Production, vol. 135, pp. 1559-1570, 2016.
[12] R. Hague*, S. Mansour, and N. Saleh, "Material and design considerations for rapid manufacturing," International Journal of Production Research, vol. 42, no. 22, pp. 4691-4708, 2004.
[13] A. Boschetto, L. Bottini, and F. Veniali, "Surface roughness and radiusing of Ti6Al4V selective laser melting-manufactured parts conditioned by barrel finishing," The International Journal of Advanced Manufacturing Technology, vol. 94, no. 5-8, pp. 2773-2790, 2018.
[14] A. Iquebal, S. Shrestha, Z. Wang, G. Manogharan, S. Bukkapatnam, and O. Youngstown, "Influence of Milling and Non-Traditional Machining on Surface Properties of Ti6Al4V EBM Components," in Proceedings of the 2016 Industrial and Systems Engineering Research Conference, 2016.
[15] J.-P. Kruth, M. Badrossamay, E. Yasa, J. Deckers, L. Thijs, and J. Van Humbeeck, "Part and material properties in selective laser melting of metals," in Proceedings of the 16th international symposium on electromachining, 2010.
[16] E. Yasa and J.-P. Kruth, "Application of laser re-melting on selective laser melting parts," Advances in Production engineering and Management, vol. 6, no. 4, pp. 259-270, 2011.
[17] A. Lamikiz, J. Sanchez, L. L. de Lacalle, and J. Arana, "Laser polishing of parts built up by selective laser sintering," International Journal of Machine Tools and Manufacture, vol. 47, no. 12-13, pp. 2040-2050, 2007.
[18] B. Rosa, P. Mognol, and J.-Y. Hascoët, "Laser polishing of additive laser manufacturing surfaces," Journal of Laser Applications, vol. 27, no. S2, p. S29102, 2015.
[19] D. Bhaduri, P. Penchev, S. Dimov, and S. Soo, "Improving the surface integrity of 3D printed stainless steel parts by laser polishing'," Proceedings of the M, vol. 4, pp. 593-596, 2015.
[20] I. Mingareev et al., "Femtosecond laser post-processing of metal parts produced by laser additive manufacturing," Journal of Laser Applications, vol. 25, no. 5, p. 052009, 2013.
[21] S. Marimuthu, A. Triantaphyllou, M. Antar, D. Wimpenny, H. Morton, and M. Beard, "Laser polishing of selective laser melted components," International Journal of Machine Tools and Manufacture, vol. 95, pp. 97-104, 2015.
[22] T. L. Perry, D. Werschmoeller, X. Li, F. E. Pfefferkorn, and N. A. Duffie, "Pulsed laser polishing of micro-milled Ti6Al4V samples," Journal of Manufacturing Processes, vol. 11, no. 2, pp. 74-81, 2009.
[23] B. Rosa, J.-Y. Hascoët, and P. Mognol, "Topography modeling of laser polishing on AISI 316L milled surfaces," Mechanics & industry, vol. 15, no. 1, pp. 51-61, 2014.
[24] S. Bagehorn, T. Mertens, D. Greitemeier, L. Carton, and A. Schoberth, "Surface finishing of additive man-ufactured ti-6al-4v–a comparison of electrochemical and mechanical treatments," in 6th Eur conf aerosp sci, 2015.
[25] A. Dolimont et al., "Influence on surface characteristics of electron beam melting process (EBM) by varying the process parameters," in AIP Conference Proceedings, 2017, vol. 1896, no. 1: AIP Publishing, p. 040010.
[26] S. Bagehorn, J. Wehr, and H. Maier, "Application of mechanical surface finishing processes for roughness reduction and fatigue improvement of additively manufactured Ti-6Al-4V parts," International Journal of Fatigue, vol. 102, pp. 135-142, 2017.
[27] F. Calignano, D. Manfredi, E. Ambrosio, L. Iuliano, and P. Fino, "Influence of process parameters on surface roughness of aluminum parts produced by DMLS," The International Journal of Advanced Manufacturing Technology, vol. 67, no. 9-12, pp. 2743-2751, 2013.
[28] B. AlMangour and J.-M. Yang, "Improving the surface quality and mechanical properties by shot-peening of 17-4 stainless steel fabricated by additive manufacturing," Materials & Design, vol. 110, pp. 914-924, 2016.
[29] A. B. Spierings, N. Herres, and G. Levy, "Influence of the particle size distribution on surface quality and mechanical properties in AM steel parts," Rapid Prototyping Journal, vol. 17, no. 3, pp. 195-202, 2011.
[30] I. V. Arasu and K. Chockalingam, "Impact of post processing parameter on mechanical properties and surface roughness of selective laser sintered sand mold casting part," 2018.
[31] A. Safdar, H. He, L.-Y. Wei, A. Snis, and L. E. Chavez de Paz, "Effect of process parameters settings and thickness on surface roughness of EBM produced Ti-6Al-4V," Rapid Prototyping Journal, vol. 18, no. 5, pp. 401-408, 2012.
[32] D. Greitemeier, C. Dalle Donne, F. Syassen, J. Eufinger, and T. Melz, "Effect of surface roughness on fatigue performance of additive manufactured Ti–6Al–4V," Materials Science and Technology, vol. 32, no. 7, pp. 629-634, 2016.
[33] H. Masuo et al., "Effects of Defects, Surface Roughness and HIP on Fatigue Strength of Ti-6Al-4V manufactured by Additive Manufacturing," Procedia Structural Integrity, vol. 7, pp. 19-26, 2017.
[34] P. Oxley, "Mechanics of Manchining, An Analytical Approach to Assessing Machinability. Halsted Press," New York, 1989.
[35] A. Daymi, M. Boujelbene, S. B. Salem, B. H. Sassi, and S. Torbaty, "Effect of the cutting speed on the chip morphology and the cutting forces," Archives of Computational Materials Science and Surface Engineering, vol. 1, no. 2, pp. 77-83, 2009.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:79806", author = "Abdulmajeed Dabwan and Saqib Anwar and Ali Al-Samhan", title = "Effects of Milling Process Parameters on Cutting Forces and Surface Roughness When Finishing Ti6al4v Produced by Electron Beam Melting", abstract = "Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology, which uses computer-controlled electron beams to create fully dense three-dimensional near-net-shaped parts from metal powder. It gives the ability to produce any complex parts directly from a computer-aided design (CAD) model without tools and dies, and with a variety of materials. However, the quality of the surface finish in EBM process has limitations to meeting the performance requirements of additively manufactured components. The aim of this study is to investigate the cutting forces induced during milling Ti6Al4V produced by EBM as well as the surface quality of the milled surfaces. The effects of cutting speed and radial depth of cut on the cutting forces, surface roughness, and surface morphology were investigated. The results indicated that the cutting speed was found to be proportional to the resultant cutting force at any cutting conditions while the surface roughness improved significantly with the increase in cutting speed and radial depth of cut.
", keywords = "Electron beam melting, additive manufacturing, Ti6Al4V, surface morphology.", volume = "14", number = "8", pages = "373-5", }
