Novel methodology for burr extension estimation on machined SLM surfaces

Novel methodology for burr extension estimation on machined SLM surfaces

GINESTRA Paola, QUARTO Mariangela, ABENI Andrea, ATTANASIO Aldo, CERETTI Elisabetta, D’URSO Gianluca, GIARDINI Claudio

download PDF

Abstract. Additive manufacturing techniques can cover the needs of these components thanks to their high level of customization of the products and the ability to realize complex shapes without high effort. Despite the benefits derived from AM processes, these techniques are characterized by a low-quality of surface finish, one of the most important requirements for medical devices. Considering this aspect, it is important to develop a solution able to improve the surface finish in order to enjoy the low lead times and the high level of customization typical of these processes. A characteristic element of micro-machining is the presence of burrs on the machined surface which can affect the surface texture of micro-features. For this reason, a novel technique for the evaluation of burr was defined. The burrs were evaluated by means of an autofocus variation digital microscope Keyence VHX-7100, on 17-4 PH steel samples produced by laser bed fusion. A 3D reconstruction of the channels and holes surfaces was performed and through the analysis of the peaks distribution, a threshold was defined to discriminate between the original surface of the part and the burrs. In this way, it was possible to estimate and approximate the value of the extension of the burrs in terms of volume and area, where the area is referred to the projected area. Specifically, in micro-machining, not only the extension of the burrs is significant, but also the variability is particularly high, preventing a priori consideration of the defect.

Additive Manufacturing, Metals, Micromachining, Surface Characterization

Published online 4/19/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: GINESTRA Paola, QUARTO Mariangela, ABENI Andrea, ATTANASIO Aldo, CERETTI Elisabetta, D’URSO Gianluca, GIARDINI Claudio, Novel methodology for burr extension estimation on machined SLM surfaces, Materials Research Proceedings, Vol. 28, pp 1323-1330, 2023


The article was published as article 143 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] C. Ransenigo, M. Tocci, F. Palo, P. Ginestra, E. Ceretti, M. Gelfi, A. Pola, Evolution of Melt Pool and Porosity During Laser Powder Bed Fusion of Ti6Al4V Alloy: Numerical Modelling and Experimental Validation, Laser. Manuf. Mater. Process. 9 (2022) 481-502.
[2] P. Ginestra, L. Riva, E. Ceretti, D. Lobo, S. Mountcastle, V. Villapun, S. Cox, L. Grover, M. Attallah, O. Addison, D. Shepherd, M. Webber, Surface finish of additively manufactured metals: Biofilm formation and cellular attachment. ESAFORM 2021 – 24th International Conference on Material Forming (2021) art. no. 2089.
[3] M. Carminati, M. Quarto, G. D’Urso, C. Giardini, C. Borriello, A Comprehensive Analysis of AISI 316L Samples Printed via FDM: Structural and Mechanical Characterization, Key Eng. Mater. 25th International Conference on Material Forming, ESAFORM (2022) 926:46-55.
[4] G. D’Urso, C. Giardini, G. Maccarini, M. Quarto, C. Ravasio, Analysis of the surface quality of steel and ceramic materials machined by micro-EDM. European Society for Precision Engineering and Nanotechnology, Conference Proceedings – 18th International Conference and Exhibition, EUSPEN, 2018.
[5] A. Abeni, P.S. Ginestra, A. Attanasio, Comparison Between Micro Machining of Additively Manufactured and Conventionally Formed Samples of Ti6Al4V Alloy, Lecture Notes in Mech. Eng. (2022) 91 – 106.
[6] P. Cardoso, J.P. Davim, A brief review on micromachining of materials, Rev. Adv. Mater. Sci. 30 (2012) 98-102.
[7] B.Z. Balázs, N. Geier, M. Takács, J.P. Davim, A review on micro-milling: recent advances and future trends, Int. J. Adv. Manuf. Technol. 112 (2021) 655–684.
[8] F. Medeossi, M. Sorgato, S. Bruschi, E. Savio, Novel method for burrs quantitative evaluation in micro-milling, Precis. Eng. 54 (2018) 379-387.
[9] F. Akkoyun, A. Ercetin, K. Aslantas, D.Y. Pimenov, K. Giasin, A. Lakshmikanthan, M. Aamir, Measurement of Micro Burr and Slot Widths through Image Processing: Comparison of Manual and Automated Measurements in Micro-Milling, Sensors. 21 (2021) 4432.
[10] A. Abeni, P.S. Ginestra, A. Attanasio, Micro-milling of Selective Laser Melted Stainless Steel, Lect. Note. Mech. Eng. (2021) 1 – 12.
[11] A.K. Yadav, M. Kumar, V. Bajpai, N.K. Singh, R.K. Singh, FE modeling of burr size in high-speed micro-milling of Ti6Al4V, Precis. Eng. 49 (2017) 287-292.
[12] Z. Kou, Y. Wan, Y. Cai, X. Liang, Z. Liu, Burr controlling in micro milling with supporting material method, Procedia Manuf. 1 (2015) 501-511.
[13] M. Malekian, M.G. Mostofa, S.S. Park, M.B.G. Jun, Modeling of minimum uncut chip thickness in micro machining of aluminum, J. Mater. Process. Technol. 212 (2012) 553-559.