Analysis of the machinability when milling AlSi10Mg additively manufactured via laser-based powder bed fusion

• Published in: International journal of advanced manufacturing technology Vol. 112; no. 3-4; pp. 989 - 1005
• Main Authors: Zimmermann, Marco, Müller, Daniel, Kirsch, Benjamin, Greco, Sebastian, Aurich, Jan C.
• Format: Journal Article
• Language: English
• Published: London Springer London 2021; Springer Nature B.V
• Subjects: Aluminum base alloys; CAE) and Design; Comminution; Computer-Aided Engineering (CAD; End milling; Engineering; Grinding mills; Industrial and Production Engineering; Laser applications; Machinability; Material properties; Mechanical Engineering; Media Management; Microhardness; Milling (machining); Morphology; Original Article; Powder beds; Production methods; Rapid prototyping; Surface roughness; Laser-based powder bed fusion; Machinability; Surface integrity; Surface quality; Milling; Burr formation
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-020-06391-7

Laser-based powder bed fusion (L-PBF) is a promising technology for the production of near net–shaped metallic components. The high surface roughness and the comparatively low-dimensional accuracy of such components, however, usually require a finishing by a subtractive process such as milling or grinding in order to meet the requirements of the application. Materials manufactured via L-PBF are characterized by a unique microstructure and anisotropic material properties. These specific properties could also affect the subtractive processes themselves. In this paper, the effect of L-PBF on the machinability of the aluminum alloy AlSi10Mg is explored when milling. The chips, the process forces, the surface morphology, the microhardness, and the burr formation are analyzed in dependence on the manufacturing parameter settings used for L-PBF and the direction of feed motion of the end mill relative to the build-up direction of the parts. The results are compared with a conventionally cast AlSi10Mg. The analysis shows that L-PBF influences the machinability. Differences between the reference and the L-PBF AlSi10Mg were observed in the chip form, the process forces, the surface morphology, and the burr formation. The initial manufacturing method of the part thus needs to be considered during the design of the finishing process to achieve suitable results.