Abstract
Selective laser melting(SLM) and direct metal laser sintering(DMLS) are preferred additive manufacturing processes in producing complex physical products directly from CAD computer data, nowadays. The advancement of additive manufacturing promotes the design of internally cooled cutting tool for effectively used in removing generated heat in metal machining. Despite the utilisation of SLM and DMLS in a fabrication of internally cooled cutting tool, the level of accuracy of the parts produced remains uncertain. This paper aims at comparing the dimensional accuracy of SLM and DMLS in machining internally cooled cutting tool with a special focus on geometrical dimensions such as hole diameter. The surface roughness produced by the two processes are measured with contact perthometer. To achieve the objectives, geometrical dimensions of identical tool holders for internally cooled cutting tools fabricated by SLM and DMLS have been determined by using digital vernier calliper and various magnification of a portable microscope. In the current study, comparing internally cooled cutting tools made of SLM and DMLS showed that generally the higher degree of accuracy could be obtained with DMLS process. However, the observed differences in surface roughness between SLM and DMLS in this study were not significant. The most obvious finding to emerge from this study is that the additive manufacturing processes selected for fabricating the tool holders for internally cooled cutting tool in this research are capable of producing the desired internal channel shape of internally cooled cutting tool.
Highlights
The temperature distribution at the tool-chip interface of a cutting tool has been a subject of investigation for many years due to resultant workpiece quality and prediction of tool wear [1, 2]
The shank is a part at where the tool holder is clamped on lathe machine
This paper discussed a dimensional accuracy of internally cooled cutting tools manufactured by Selective Laser Melting (SLM) and direct metal laser sintering (DMLS) process
Summary
The temperature distribution at the tool-chip interface of a cutting tool has been a subject of investigation for many years due to resultant workpiece quality and prediction of tool wear [1, 2]. The conventional method, which is often called flood cooling, is using dousing a large quantity of cutting fluid, usually a mixture of oil and water, to the area in the vicinity of the tool-chip contact region. Cutting fluid or addressed as metal working fluid (MWF) in several kinds of literature has been reported to have various adverse effects when in use abundantly [3]. Based on the report by Canter [5] in 1999, Metalworking Fluids Standards Advisory Committee (MWFSAC) had recommended that the permissible exposure limit for metal working fluids be 0.5 mg/m3. Byrne, Dornfeld [4], Sreejith and Ngoi [6], and Wardle, Minton [7] have suggested that dry cutting, a machining process without the presence of external cutting fluid to be the desirable machining approach for the manufacturing industry for producing components and products, to satisfy both ecological and economical requirements
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
