Evaluation of Surface Roughness and Defect Formation after The Machining of Sintered Aluminum Alloy AlSi10Mg.

Grzegorz Struzikiewicz,Andrzej Sioma

doi:10.3390/ma13071662

Abstract

This article presents selected issues related to the workpiece surface quality after machining by the laser sintering of AlSi10MG alloy powder. The surfaces of the workpiece were prepared and machined by longitudinal turning with tools made of sintered carbides. The occurrence of breaches on the machined material surface was found, which negatively influence the values of 3D surface roughness parameters. The occurring phenomena were analyzed and proposals for their explanation were made. Guidelines for the machining of workpieces achieved by the laser sintering of powders were developed. The lowest value of the 3D roughness parameters was obtained for f = 0.06 mm/rev, ap = 0.5–1.0 mm, and for the nose radius of cutting insert rε = 0.8 mm. The results of research on the effect of cutting parameters on the values of parameters describing the surface quality are presented. Topography measurements and 3D surface roughness parameters are presented, as well as the results of a microscopic 3D surface analysis. Taguchi’s method was used in the research methodology.

Highlights

The aim of currently observed directions and development trends visible in manufacturing techniques is to meet the requirements for dimension and shape accuracy and surface quality
The hybrid manufacturing consists of the printing of a workpiece or its piece, and carrying out the final machining in the form of the burr removal of selected surfaces in order to ensure the required accuracy and quality level
The results showed that 15 nm Ra surface roughness were obtained on V-groove surface under the best machining condition

Summary

Introduction

The aim of currently observed directions and development trends visible in manufacturing techniques is to meet the requirements for dimension and shape accuracy and surface quality. One of the solutions used is a hybrid machining that combines subtractive manufacturing with additive machining. In this case, the hybrid manufacturing consists of the printing (additive manufacturing) of a workpiece or its piece, and carrying out the final machining in the form of the burr removal (subtractive machining) of selected surfaces in order to ensure the required accuracy and quality level. The combination of subtractive machining with AM (Additive Manufacturing) is beneficial in terms of manufacturing costs of machine parts [1]. This mainly concerns the manufacturing of large-size workpieces with thin-walled elements

Methods

Discussion

Conclusion