Machining strategy determination for single- and multi-material wire and arc additive manufactured thin-walled parts

Ozaner, Ozan Can (author), Klobčar, Damjan (author), Sharma, Abhay (author)

Wire and arc additive manufacturing (WAAM) technology has recently become attractive due to the fact of its high production capacity and flexible deposition strategy. One of the most prominent drawbacks of WAAM is surface irregularity. Therefore, WAAMed parts cannot be used as built; they require secondary machining operations. However, performing such operations is challenging due to the fact of high waviness. Selecting an appropriate cutting strategy is also challenging, because surface irregularity makes cutting forces unstable. The present research determines the most suitable machining strategy by assessing the specific cutting energy and local machined volume. Up- and down-milling are evaluated by calculating the removed volume and specific cutting energy for creep-resistant steel, stainless steel, and their combination. It is shown that the main factors that affect the machinability of WAAMed parts are the machined volume and specific cutting energy rather than the axial and radial depths of the cut due to the fact of high surface irregularity. Even though the results were unstable, a surface roughness of 0.1 µm was obtained with up-milling. Despite a two-fold difference in the hardness between the two materials in the multi-material deposition, it is found that hardness should not be used as a criterion for as-built surface processing. In addition, the results show no machinability difference between multi- and single-material components for a low machined volume and low surface irregularity.

• Language: English
• Keywords: bimetallic, specific cutting energy, machinability, WAAM, additive manufacturing, surface integrity
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2023
• Number of pages: 20 str.
• Numbering: Vol. 16, iss. 5, art. 2055
• PID: 20.500.12556/RUL-144626
• UDC: 621.7+621.9
• ISSN on article: 1996-1944
• DOI: 10.3390/ma16052055
• COBISS.SI-ID: 143970819
• Publication date in RUL: 03.03.2023

Record is a part of a journal

• Title: Materials
• Shortened title: Materials
• Publisher: MDPI
• ISSN: 1996-1944
• COBISS.SI-ID: 33588485

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Keywords: bimetali, specifična rezalna energija, mehanska obdelava, oblikovno obločno navarjanje, aditivne tehnologije, integriteta površin

Projects

• Funder: Other - Other funder or multiple funders
• Funding programme: CELSA
• Project number: 3E210629
• Name: Fundamental Study on Next Generation Multi-Material Wire-Arc Additive Manufacturing

• Funder: ARRS - Slovenian Research Agency
• Project number: P2-0270
• Name: Proizvodni sistemi, laserske tehnologije in spajanje materialov