Abstract

Hybrid additive/subtractive manufacturing (ASHM) is recently developed to fabricate complex structures. High thermal gradient during the SLM process leads to large residual stresses, which could affect the surface quality of subjacent milled surfaces. This paper focuses on the surface quality of overhang features in selective laser melting (SLM)-based ASHM. An ASHM experiment with overhang feature was conducted for 6511 steel. A 3D thermo-mechanical coupled finite element (FE) model of SLM considering phase transformation of 6511 was established. The effects of volumetric change due to phase transformation on surface quality were studied. The predicted overhang surface quality was compared with that from the experiment. This paper could provide guidance to the process planning of ASHM with overhang features.

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