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THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING

Yıl 2021, Cilt: 5 Sayı: 2, 187 - 194, 31.08.2021
https://doi.org/10.46519/ij3dptdi.947650

Öz

The most critical component of Industry 4.0, the new face of the machinery-manufacturing industry sector, is metal additive manufacturing. Laser-based additive manufacturing techniques are dominant for metal additive manufacturing today. In this study, the metal alloy studied is Ti-6Al-4V, one of the essential Ti alloys used in more than 50% of all commercial Ti applications. Ti-6Al-4V parts produced by additive manufacturing are used in the biomedical, aerospace-defence industry, and industrial areas due to their high strength, fatigue behaviour, fracture strength, good corrosion resistance, and biocompatibility. In the study, samples of Ti6Al4V alloy were produced with different manufacturing parameters by the direct metal laser sintering (DMLS) method, which is one of the powder bed fusion methods. Then, the surface qualities of the samples were processed by milling and wire EDM. The effects of machining operations on the surface roughness of the samples were investigated and compared with the surface roughness obtained from the samples produced by the DMLS method. After the optical microscope images of the samples were taken, the physical and surface morphology were examined. Although the mechanical properties of the parts manufactured by DMLS methods were higher, the samples with machining presented higher machinability with lower forces, lower surface roughness. the This is explained that mechanical properties of samples of Ti6Al4V alloy in additive manufacturing are highly dependent on the rapid cooling of the material. Results show that samples of Ti6Al4V manufactured by additive manufacturing has been possible using with machining.

Kaynakça

  • 1. Tezel, T., Topal, E.S., Kovan, V., “Hibrit imalat: Eklemeli imalat ile talaşlı imalat yöntemlerinin birlikte kullanılabilirliğinin incelenmesi”, International Journal of 3D Printing Technologies and Digital Industry, Cilt 2, Sayı 3, Sayfa 60-65, 2018.
  • 2. Erçetin, A., Aslantas, K., Özgün, Ö., “Micro-end milling of biomedical TZ54 magnesium alloy produced through powder metallurgy”, Machining Science and Technology, Vol. 24, Issue 6, Pages 924-947, 2020.
  • 3. Akkoyun, F., Ercetin, A., Aslantas, K., Pimenov, D.Y., Giasin, K., Lakshmikanthan, A., Aamir, M. “Measurement of micro burr and slot widths through image processing: Comparison of manual and automated measurements in micro-milling”, Sensors, Vol. 21, Issue 13, Pages 4432, 2021.
  • 4. Kuntoğlu, M., Acar, O., Gupta, M.K., Sağlam, H., Sarikaya, M., Giasin, K., Pimenov, D.Y. “Parametric optimization for cutting forces and material removal rate in the turning of AISI 5140”, Machines, Vol. 9, Issue 5, Pages 90, 2021.
  • 5. Duman, B., Kayacan, M.C., “Doğrudan metal lazer sinterleme ergitme yöntemi ile imal edilecek parçanın mekanik özelliklerinin tahmini”, SDÜ Teknik Bilimler Dergisi, Cilt 7, Sayı 1, Sayfa 12–20, 2017.
  • 6. Karakılınç U., Yalçın B. ve Ergene B., “Toz yataklı/beslemeli eklemeli imalatta kullanılan partiküllerin uygunluk araştırması ve partikül imalat yöntemleri”, Politeknik Dergisi, Cilt 22, Sayı 4, Sayfa 801-810, 2019.
  • 7. Eklemeli Imalat Teknolojileri Yol Haritasi (Eityh) Odak Teknoloji Aği (Otağ) Sonuç Raporu, https://arge.ssb.gov.tr/Documents/Eklemeli_Imalat%20_Teknolojileri_OTAG_Sonuc_Raporu.pdf , August 5, 2021.
  • 8. Yalçın, B., Ergene, B., “Endüstride yeni eğilim olan 3-D eklemeli imalat yöntemi ve metalurjisi”, Uluslararası Teknolojik Bilimler Dergisi, Cilt 9, Sayı 3, Sayfa 65-88, 2017.
  • 9. Oter, Z.C., Coskun, M., Akca, Y., Sürmen, Ö., Yılmaz, M.S., Özer, G., & Koc, E. “Benefits of laser beam based additive manufacturing in die production”, Optik, Vol. 176, Pages 175-184, 2019.
  • 10. Yasa, E., Kruth, J.P., “Microstructural investigation of Selective Laser Melting 316L stainless steel parts exposed to laser re-melting”, Procedia Engineering, Vol. 19, Pages 389-395, 2011.
  • 11. Kas, M., Yilmaz, O., “Radially graded porous structure design for laser powder bed fusion additive manufacturing of Ti-6Al-4V alloy”, Journal of Materials Processing Technology, Vol. 296, 117186, 2021.
  • 12. Sagbas¸ B., “Post-processing effects on surface properties of direct metal laser sintered AlSi10Mg parts”, Metals and Materials International, Vol. 26, Pages 143–153, 2020.
  • 13. Wang, Y., Chen, X., Shen, Q., Su, C., Zhang, Y., Jayalakshmi, S., Singh, R.A., “Effect of magnetic Field on the microstructure and mechanical properties of Inconel 625 superalloy fabricated by wire arc additive manufacturing”, Journal of Manufacturing Processes, Vol. 64, Pages 10-19, 2021.
  • 14. Jevremović, D., Kojić, V., Bogdanović, G., Puškar, T., Eggbeer, D., Thomas, D., Williams, R. (2011). A selective laser melted Co-Cr alloy used for the rapid manufacture of removable partial denture frameworks: Initial screening of biocompatibility. Journal of the Serbian Chemical Society, Vol. 76, Issue 1, Pages 43-52.
  • 15. Kayacan, M., Delikanlı, Y., Duman, B., Özsoy, K., “Ti6Al4V toz alaşımı kullanılarak sls ile üretilen geçişli (değişken) gözenekli numunelerin mekanik özelliklerinin incelenmesi”, Journal of the Faculty of Engineering and Architecture of Gazi University, Vol. 33, Issue 1, Pages 127-143, 2018.
  • 16. Kumbhar, N.N., Mulay, A.V., “Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: A review”, Journal of The Institution of Engineers India: Series C, Vol. 99, Issue 4, Pages 481–487, 2016.
  • 17. Ermergen, T., Taylan, F., “Eklemeli imalat ile imal edilmiş metal parçalara uygulanan yüzey bitirme işlemleri”, SDU Uluslararası Teknolojik Bilimler Dergisi, Cilt 12, Sayı 1, Sayfa 45-55, 2020.
  • 18. Ratnam, M.M., “Factors affecting surface roughness in finish turning”, Comprehensive Material Finishing, Vol. 1, Pages 1-25, 2017.
  • 19. de Oliveira Campos, F., Araujo, A. C., Munhoz, A. L. J., Kapoor, S. G. “The influence of additive manufacturing on the micromilling machinability of Ti6Al4V: A comparison of SLM and commercial workpieces”, Journal of Manufacturing Processes, Vol. 60, Pages 299-307, 2020.
  • 20. He, C.L., Zong, W.J., Zhang, J.J., “Influencing factors and theoretical modeling methods of surface roughness in turning process: State-of-the-art”, International Journal of Machine Tools and Manufacture, Vol. 129, Pages 15-26, 2018.
  • 21. Electro Optical Systems. Material data sheet: EOS Titanium Ti64. Munich, Germany: EOS. http://gpiprototype.com/images/PDF/ EOS_Titanium_Ti64_en.pdf. Accessed May 2, 2021.
  • 22. Greitemeier, D., Dalle Donne, C., Syassen, F., Eufinger, J., Melz, T., “Effect of surface roughness on fatigue performance of additive manufactured Ti–6Al–4V”, Materials Science and Technology, Vol. 32, Issue 7, Pages 629-634, 2016.
  • 23. Nicoletto, G., Konečná, R., Frkáň, M., Riva, E. (2018). “Surface roughness and directional fatigue behavior of as-built EBM and DMLS Ti6Al4V”, International journal of fatigue, Vol. 116, 140-148.
  • 24. Sharma, M., & Soni, M., “Direct metal laser sintering of Ti6Al4V alloy for patient-specific temporo mandibular joint prosthesis and implant”, Materials Today: Proceedings, Vol. 38, Pages 333-339, 2021.
  • 25. Erçetin, A., Aslantaş, K., Perçin, M., “Micro milling of tungsten-copper composite materials produced through powder metallurgy method: Effect of composition and sintering temperature”, Journal of the Faculty of Engineering and Architecture of Gazi University, Vol. 33, Issue 4, Pages 1369-1381, 2018.
  • 26. Cabanettes, F., Joubert, A., Chardon, G., Dumas, V., Rech, J., Grosjean, C., Dimkovski, Z. “Topography of as built surfaces generated in metal additive manufacturing: A multi scale analysis from form to roughness”, Precision Engineering, Vol. 52, Pages 249-265, 2018.

THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING

Yıl 2021, Cilt: 5 Sayı: 2, 187 - 194, 31.08.2021
https://doi.org/10.46519/ij3dptdi.947650

Öz

The most critical component of Industry 4.0, the new face of the machinery-manufacturing industry sector, is metal additive manufacturing. Laser-based additive manufacturing techniques are dominant for metal additive manufacturing today. In this study, the metal alloy studied is Ti-6Al-4V, one of the essential Ti alloys used in more than 50% of all commercial Ti applications. Ti-6Al-4V parts produced by additive manufacturing are used in the biomedical, aerospace-defence industry, and industrial areas due to their high strength, fatigue behaviour, fracture strength, good corrosion resistance, and biocompatibility. In the study, samples of Ti6Al4V alloy were produced with different manufacturing parameters by the direct metal laser sintering (DMLS) method, which is one of the powder bed fusion methods. Then, the surface qualities of the samples were processed by milling and wire EDM. The effects of machining operations on the surface roughness of the samples were investigated and compared with the surface roughness obtained from the samples produced by the DMLS method. After the optical microscope images of the samples were taken, the physical and surface morphology were examined. Although the mechanical properties of the parts manufactured by DMLS methods were higher, the samples with machining presented higher machinability with lower forces, lower surface roughness. the This is explained that mechanical properties of samples of Ti6Al4V alloy in additive manufacturing are highly dependent on the rapid cooling of the material. Results show that samples of Ti6Al4V manufactured by additive manufacturing has been possible using with machining.

Kaynakça

  • 1. Tezel, T., Topal, E.S., Kovan, V., “Hibrit imalat: Eklemeli imalat ile talaşlı imalat yöntemlerinin birlikte kullanılabilirliğinin incelenmesi”, International Journal of 3D Printing Technologies and Digital Industry, Cilt 2, Sayı 3, Sayfa 60-65, 2018.
  • 2. Erçetin, A., Aslantas, K., Özgün, Ö., “Micro-end milling of biomedical TZ54 magnesium alloy produced through powder metallurgy”, Machining Science and Technology, Vol. 24, Issue 6, Pages 924-947, 2020.
  • 3. Akkoyun, F., Ercetin, A., Aslantas, K., Pimenov, D.Y., Giasin, K., Lakshmikanthan, A., Aamir, M. “Measurement of micro burr and slot widths through image processing: Comparison of manual and automated measurements in micro-milling”, Sensors, Vol. 21, Issue 13, Pages 4432, 2021.
  • 4. Kuntoğlu, M., Acar, O., Gupta, M.K., Sağlam, H., Sarikaya, M., Giasin, K., Pimenov, D.Y. “Parametric optimization for cutting forces and material removal rate in the turning of AISI 5140”, Machines, Vol. 9, Issue 5, Pages 90, 2021.
  • 5. Duman, B., Kayacan, M.C., “Doğrudan metal lazer sinterleme ergitme yöntemi ile imal edilecek parçanın mekanik özelliklerinin tahmini”, SDÜ Teknik Bilimler Dergisi, Cilt 7, Sayı 1, Sayfa 12–20, 2017.
  • 6. Karakılınç U., Yalçın B. ve Ergene B., “Toz yataklı/beslemeli eklemeli imalatta kullanılan partiküllerin uygunluk araştırması ve partikül imalat yöntemleri”, Politeknik Dergisi, Cilt 22, Sayı 4, Sayfa 801-810, 2019.
  • 7. Eklemeli Imalat Teknolojileri Yol Haritasi (Eityh) Odak Teknoloji Aği (Otağ) Sonuç Raporu, https://arge.ssb.gov.tr/Documents/Eklemeli_Imalat%20_Teknolojileri_OTAG_Sonuc_Raporu.pdf , August 5, 2021.
  • 8. Yalçın, B., Ergene, B., “Endüstride yeni eğilim olan 3-D eklemeli imalat yöntemi ve metalurjisi”, Uluslararası Teknolojik Bilimler Dergisi, Cilt 9, Sayı 3, Sayfa 65-88, 2017.
  • 9. Oter, Z.C., Coskun, M., Akca, Y., Sürmen, Ö., Yılmaz, M.S., Özer, G., & Koc, E. “Benefits of laser beam based additive manufacturing in die production”, Optik, Vol. 176, Pages 175-184, 2019.
  • 10. Yasa, E., Kruth, J.P., “Microstructural investigation of Selective Laser Melting 316L stainless steel parts exposed to laser re-melting”, Procedia Engineering, Vol. 19, Pages 389-395, 2011.
  • 11. Kas, M., Yilmaz, O., “Radially graded porous structure design for laser powder bed fusion additive manufacturing of Ti-6Al-4V alloy”, Journal of Materials Processing Technology, Vol. 296, 117186, 2021.
  • 12. Sagbas¸ B., “Post-processing effects on surface properties of direct metal laser sintered AlSi10Mg parts”, Metals and Materials International, Vol. 26, Pages 143–153, 2020.
  • 13. Wang, Y., Chen, X., Shen, Q., Su, C., Zhang, Y., Jayalakshmi, S., Singh, R.A., “Effect of magnetic Field on the microstructure and mechanical properties of Inconel 625 superalloy fabricated by wire arc additive manufacturing”, Journal of Manufacturing Processes, Vol. 64, Pages 10-19, 2021.
  • 14. Jevremović, D., Kojić, V., Bogdanović, G., Puškar, T., Eggbeer, D., Thomas, D., Williams, R. (2011). A selective laser melted Co-Cr alloy used for the rapid manufacture of removable partial denture frameworks: Initial screening of biocompatibility. Journal of the Serbian Chemical Society, Vol. 76, Issue 1, Pages 43-52.
  • 15. Kayacan, M., Delikanlı, Y., Duman, B., Özsoy, K., “Ti6Al4V toz alaşımı kullanılarak sls ile üretilen geçişli (değişken) gözenekli numunelerin mekanik özelliklerinin incelenmesi”, Journal of the Faculty of Engineering and Architecture of Gazi University, Vol. 33, Issue 1, Pages 127-143, 2018.
  • 16. Kumbhar, N.N., Mulay, A.V., “Post processing methods used to improve surface finish of products which are manufactured by additive manufacturing technologies: A review”, Journal of The Institution of Engineers India: Series C, Vol. 99, Issue 4, Pages 481–487, 2016.
  • 17. Ermergen, T., Taylan, F., “Eklemeli imalat ile imal edilmiş metal parçalara uygulanan yüzey bitirme işlemleri”, SDU Uluslararası Teknolojik Bilimler Dergisi, Cilt 12, Sayı 1, Sayfa 45-55, 2020.
  • 18. Ratnam, M.M., “Factors affecting surface roughness in finish turning”, Comprehensive Material Finishing, Vol. 1, Pages 1-25, 2017.
  • 19. de Oliveira Campos, F., Araujo, A. C., Munhoz, A. L. J., Kapoor, S. G. “The influence of additive manufacturing on the micromilling machinability of Ti6Al4V: A comparison of SLM and commercial workpieces”, Journal of Manufacturing Processes, Vol. 60, Pages 299-307, 2020.
  • 20. He, C.L., Zong, W.J., Zhang, J.J., “Influencing factors and theoretical modeling methods of surface roughness in turning process: State-of-the-art”, International Journal of Machine Tools and Manufacture, Vol. 129, Pages 15-26, 2018.
  • 21. Electro Optical Systems. Material data sheet: EOS Titanium Ti64. Munich, Germany: EOS. http://gpiprototype.com/images/PDF/ EOS_Titanium_Ti64_en.pdf. Accessed May 2, 2021.
  • 22. Greitemeier, D., Dalle Donne, C., Syassen, F., Eufinger, J., Melz, T., “Effect of surface roughness on fatigue performance of additive manufactured Ti–6Al–4V”, Materials Science and Technology, Vol. 32, Issue 7, Pages 629-634, 2016.
  • 23. Nicoletto, G., Konečná, R., Frkáň, M., Riva, E. (2018). “Surface roughness and directional fatigue behavior of as-built EBM and DMLS Ti6Al4V”, International journal of fatigue, Vol. 116, 140-148.
  • 24. Sharma, M., & Soni, M., “Direct metal laser sintering of Ti6Al4V alloy for patient-specific temporo mandibular joint prosthesis and implant”, Materials Today: Proceedings, Vol. 38, Pages 333-339, 2021.
  • 25. Erçetin, A., Aslantaş, K., Perçin, M., “Micro milling of tungsten-copper composite materials produced through powder metallurgy method: Effect of composition and sintering temperature”, Journal of the Faculty of Engineering and Architecture of Gazi University, Vol. 33, Issue 4, Pages 1369-1381, 2018.
  • 26. Cabanettes, F., Joubert, A., Chardon, G., Dumas, V., Rech, J., Grosjean, C., Dimkovski, Z. “Topography of as built surfaces generated in metal additive manufacturing: A multi scale analysis from form to roughness”, Precision Engineering, Vol. 52, Pages 249-265, 2018.
Toplam 26 adet kaynakça vardır.

Ayrıntılar

Birincil Dil İngilizce
Konular Mühendislik
Bölüm Araştırma Makalesi
Yazarlar

Zihni Alp Çevik 0000-0003-3141-0160

Koray Özsoy 0000-0001-8663-4466

Ali Erçetin 0000-0002-7631-1361

Yayımlanma Tarihi 31 Ağustos 2021
Gönderilme Tarihi 3 Haziran 2021
Yayımlandığı Sayı Yıl 2021 Cilt: 5 Sayı: 2

Kaynak Göster

APA Çevik, Z. A., Özsoy, K., & Erçetin, A. (2021). THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING. International Journal of 3D Printing Technologies and Digital Industry, 5(2), 187-194. https://doi.org/10.46519/ij3dptdi.947650
AMA Çevik ZA, Özsoy K, Erçetin A. THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING. IJ3DPTDI. Ağustos 2021;5(2):187-194. doi:10.46519/ij3dptdi.947650
Chicago Çevik, Zihni Alp, Koray Özsoy, ve Ali Erçetin. “THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING”. International Journal of 3D Printing Technologies and Digital Industry 5, sy. 2 (Ağustos 2021): 187-94. https://doi.org/10.46519/ij3dptdi.947650.
EndNote Çevik ZA, Özsoy K, Erçetin A (01 Ağustos 2021) THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING. International Journal of 3D Printing Technologies and Digital Industry 5 2 187–194.
IEEE Z. A. Çevik, K. Özsoy, ve A. Erçetin, “THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING”, IJ3DPTDI, c. 5, sy. 2, ss. 187–194, 2021, doi: 10.46519/ij3dptdi.947650.
ISNAD Çevik, Zihni Alp vd. “THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING”. International Journal of 3D Printing Technologies and Digital Industry 5/2 (Ağustos 2021), 187-194. https://doi.org/10.46519/ij3dptdi.947650.
JAMA Çevik ZA, Özsoy K, Erçetin A. THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING. IJ3DPTDI. 2021;5:187–194.
MLA Çevik, Zihni Alp vd. “THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING”. International Journal of 3D Printing Technologies and Digital Industry, c. 5, sy. 2, 2021, ss. 187-94, doi:10.46519/ij3dptdi.947650.
Vancouver Çevik ZA, Özsoy K, Erçetin A. THE EFFECT OF MACHINING PROCESSES ON THE PHYSICAL AND SURFACE MORPHOLOGY OF Ti6Al4V SPECIMENS PRODUCED THROUGH POWDER BED FUSION ADDITIVE MANUFACTURING. IJ3DPTDI. 2021;5(2):187-94.

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