Abstract
In manufacturing, hybrid systems of metal additive manufacturing and cutting in the same platform have been attractive in terms of low volume production of customized parts, complex shape, and fine surface finish. Milling is conducted to finish rough surface fabricated in additive process. The fundamental machinability of the additive workpiece should be studied because the material properties are different from metals produced in the conventional process. The paper discusses the cutting forces in milling of AISI 420 stainless steel fabricated in additive process. The cutting tests were conducted to measure the cutting forces and the chip morphologies for tool geometries. The cutting forces were also analyzed in an energy-based force model. In the analysis model, three-dimensional chip flow is interpreted as a piling up of orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities, where the cutting model is made by the orthogonal cutting data acquired in cutting tests. The chip flow direction is determined to minimize the cutting energy. The cutting forces, then, were predicted in the determined chip flow model. The cutting force model was validated in comparison of simulated forces with the actual ones.
Highlights
Martensitic stainless steel has been widely used for applications including injection molds and dies, dental and surgical instruments due to the high strength with the good corrosion resistance
Machinability of AISI 420 martensitic stainless steel fabricated selective laser melting (SLM) has been discussed in the cutting tests and the simulation
The force model based on the minimum cutting energy was applied to the simulation of milling
Summary
Martensitic stainless steel has been widely used for applications including injection molds and dies, dental and surgical instruments due to the high strength with the good corrosion resistance. Zhao et al fabricated an injection mold insert of AISI 420 with complex cooling channels with SLM, and the hardness increased at a high laser power for phase composition [11]. Montevecchi et al compared the cutting forces in milling of AISI H13 steels processed in LENS and wire-arc additive manufacturing (WAAM). The paper investigates machinability of AISI 420 stainless fabricated by SLM steel in milling process. The workpieces of AISI 420 stainless steel fabricated SLM (SLM workpiece) were prepared for the cutting tests in LPBF process on an AM machine (Sodic OPM250L). The SLM workpiece was approximately 2.5 times larger than the wrought one
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