LAPSE:2023.35109
Published Article
LAPSE:2023.35109
CNC Turning of an Additively Manufactured Complex Profile Ti6Al4V Component Considering the Effect of Layer Orientations
April 28, 2023
Electron beam melting (EBM) is one example of a 3D printing technology that has shown great promise and advantages in the fabrication of medical devices such as dental and orthopedic implants. However, these products require high surface quality control to meet the specifications; thus, post-processing, such as with machining processes, is required to improve surface quality. This paper investigates the influence of two-part orientations of Ti6Al4V EBM parts on the CNC machining (turning) process. The two possible EBM part orientations used in this work are across EBM layers (AL) and parallel to the EBM layer (PL). The effect of the EBM Ti6Al4V part orientations is examined on surface roughness, power consumption, chip morphology, tool flank wear, and surface morphology during the dry turning, while using uncoated carbide tools at different feed rates and cutting speeds. The results showed that the AL orientation had better surface quality control and integrity after machining than PL orientation. Using the same turning parameters, the difference between the roughness (Ra) value for AL (0.36 μm) and PL (0.79 μm) orientations is about 54%. Similarly, the power consumption in AL orientation differs by 19% from the power consumption in PL orientation. The chip thickness ratio has a difference of 23% between AL and PL orientations, and the flank wear shows a 40% difference between AL and PL orientations. It is found that, when EBM components are manufactured along across-layer (AL) orientations, the impact of part orientation during turning is minimized and machined surface integrity is improved.
Keywords
3D printing, across layer (AL) orientation, CNC machining, electron beam melting (EBM), parallel layer (PL) orientation, surface quality control, Ti6Al4V
Suggested Citation
Dabwan A, Anwar S, Al-Samhan AM, Alqahtani KN, Nasr MM, Kaid H, Ameen W. CNC Turning of an Additively Manufactured Complex Profile Ti6Al4V Component Considering the Effect of Layer Orientations. (2023). LAPSE:2023.35109
Author Affiliations
Dabwan A: Industrial Engineering Department, College of Engineering, Taibah University, Medinah 41411, Saudi Arabia
Anwar S: Industrial Engineering Department, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia [ORCID]
Al-Samhan AM: Industrial Engineering Department, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia [ORCID]
Alqahtani KN: Industrial Engineering Department, College of Engineering, Taibah University, Medinah 41411, Saudi Arabia [ORCID]
Nasr MM: Industrial Engineering Department, College of Engineering, Taibah University, Medinah 41411, Saudi Arabia [ORCID]
Kaid H: Industrial Engineering Department, College of Engineering, Taibah University, Medinah 41411, Saudi Arabia [ORCID]
Ameen W: Industrial Engineering Department, College of Engineering and Architecture, Alyamamah University, Riyadh 11512, Saudi Arabia
Journal Name
Processes
Volume
11
Issue
4
First Page
1031
Year
2023
Publication Date
2023-03-29
Published Version
ISSN
2227-9717
Version Comments
Original Submission
Other Meta
PII: pr11041031, Publication Type: Journal Article
Record Map
Published Article

LAPSE:2023.35109
This Record
External Link

doi:10.3390/pr11041031
Publisher Version
Download
Files
[Download 1v1.pdf] (7.7 MB)
Apr 28, 2023
Main Article
License
CC BY 4.0
Meta
Record Statistics
Record Views
76
Version History
[v1] (Original Submission)
Apr 28, 2023
 
Verified by curator on
Apr 28, 2023
This Version Number
v1
Citations
Most Recent
This Version
URL Here
https://psecommunity.org/LAPSE:2023.35109
 
Original Submitter
Auto Uploader for LAPSE
Links to Related Works
Directly Related to This Work
Publisher Version