Micro-milling and micro-EDM residual stresses evaluation on post-processed 3D printed samples

–

Micro-milling and micro-EDM residual stresses evaluation on post-processed 3D printed samples

HIKARU Abe, BINTI JUANIH Iman Farhana, QUARTO Mariangela, ABENI Andrea, ATTANASIO Aldo, D’URSO Gianluca, GINESTRA Paola, MATSUMURA Takashi

Abstract. Micromachining is essential for producing microscopic components or obtaining complicated details in high-precision devices. Micromachining on 3D-printed metal samples is a cutting-edge, interdisciplinary field that blends additive manufacturing with accurate subtractive machining processes at the microscale. This method aims to precisely remove material from 3D-Printed metal items to obtain complicated geometries with strict tolerances, and high-end surface finishes. The surface integrity is not only determined by the surface roughness, but it depends also on the residual stresses caused by the thermo-mechanical loads during the Additive Manufacturing and the Micromachining processes. This paper aims to analyze the residual stresses measurements after Micromachining with both Micro-Milling and Micro-Electrical Discharge Machining of 3D-Printed metal samples. 17-4 PH stainless steel 3D printed samples were produced with Laser Powder Bed Fusion. The analysis of the residual stresses was carried out by producing microchannels of different sizes (200 μm and 800 μm) to also investigate the scale effect.

Keywords
Micro Milling, Micro-EDM, Residual Stress, 3D Printed Metals

Published online 4/24/2024, 7 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: HIKARU Abe, BINTI JUANIH Iman Farhana, QUARTO Mariangela, ABENI Andrea, ATTANASIO Aldo, D’URSO Gianluca, GINESTRA Paola, MATSUMURA Takashi, Micro-milling and micro-EDM residual stresses evaluation on post-processed 3D printed samples, Materials Research Proceedings, Vol. 41, pp 1860-1866, 2024

DOI: https://doi.org/10.21741/9781644903131-206

The article was published as article 206 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.

References
[1] A., Abeni, P.S., Ginestra, A. Attanasio. Micro-milling of Selective Laser Melted Stainless Steel. In: Ceretti, E., Tolio, T. (eds) Selected Topics in Manufacturing. Lecture Notes in Mechanical Engineering. (2021) Springer, Cham. https://doi.org/10.1007/978-3-030-57729-2_1
[2] M., Quarto, G. Maccarini. Surface Quality Improvement Techniques for 3D Printed Metal Samples. In: Carrino, L., Galantucci, L.M., Settineri, L. (eds) Selected Topics in Manufacturing. Lecture Notes in Mechanical Engineering. (2024) Springer, Cham. https://doi.org/10.1007/978-3-031-41163-2_3
[3] C. Li, Z.Y. Liu, X.Y. Fang, Y.B. Guo, Residual Stress in Metal Additive Manufacturing, Procedia CIRP, Volume 71, (2018) Pages 348-353, ISSN 2212-8271, https://doi.org/10.1016/j.procir.2018.05.039
[4] E.S.; Statnik, F.; Uzun, S.A.; Lipovskikh, Y.V.; Kan, S.I.; Eleonsky, V.S.; Pisarev, P.A.; Somov, A.I.; Salimon, Y.V.; Malakhova, A.G.; Seferyan, et al. Comparative Multi-Modal, Multi-Scale Residual Stress Evaluation in SLM 3D-Printed Al-Si-Mg Alloy (RS-300) Parts. Metals (2021) 11, 2064. https://doi.org/10.3390/met11122064
[5] QP Ma, J Mesicek, F Fojtik, J Hajnys, P Krpec, M Pagac, J Petru. Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method. Materials (Basel). (2022) Sep 1;15(17):6057. doi: 10.3390/ma15176057. PMID: 36079438; PMCID: PMC9457910
[6] A., Abeni, M. Quarto, & P.S Ginestra. Post-processing of powder bed fused stainless steel: micro-machining and micro-electrical discharge machining. J Intell Manuf (2023). https://doi.org/10.1007/s10845-023-02277-z
[7] S. Tamura, A. Ezura, and T. Matsumura, “Cutting Force in Peripheral Milling of Additively Manufactured Maraging Steel,” Int. J. Automation Technol., (2022) Vol.16 No.6, pp. 897-905,
[8] S. Schneider, J. Vorspohl, F. Frerichs, A. Klink, M. Meinke, W. Schröder, T. Lübben, Investigation on residual stress induced by multiple EDM discharges, Procedia CIRP, Volume 102, (2021), Pages 482-487, ISSN 2212-8271, https://doi.org/10.1016/j.procir.2021.09.082.
[9] H., Liu, D.Schraknepper , T. Bergs. Investigation of residual stresses and workpiece distortion during high-feed milling of slender stainless steel components. Procedia CIRP, 108, (2022). 495-500.
[10] S. K.,Rajbongshi, D. K., Sarma, M. A. Singh. (A Brief Review of White Layer Formation in Hard Machining with a Case Study. In Advances in Mechanical Engineering: Select Proceedings of ICRIDME (2020). pp. 407-417. Springer Singapore.
[11] R. Acevedo, P. Sedlak, R. Kolman, M. Fredel, Residual stress analysis of additive manufacturing of metallic parts using ultrasonic waves: State of the art review, Journal of Materials Research and Technology, Volume 9, Issue 4, (2020), Pages 9457-9477, ISSN 2238-7854, https://doi.org/10.1016/j.jmrt.2020.05.092
[12] R., Yadav, N.D. Chakladar, S. Paul. Effects of tailored residual stress on micro-end milling: numerical modelling and validation. Int J Adv Manuf Technol 127, 5449–5470 (2023). https://doi.org/10.1007/s00170-023-11780-9