研究目的
To fabricate Ti-6Al-4V workpieces using the DED method of AM and to analyze the machining characteristics by LAM of the fabricated workpieces.
研究成果
The study successfully fabricated Ti-6Al-4V workpieces using the DED method and analyzed the machining characteristics by LAM. The cutting force dramatically decreased by more than 40% with laser preheating, and the surface roughness significantly decreased by about 30%. The tensile strength was 20% higher than ASTM standard, indicating the potential for commercial use. No significant change in hardness was observed after machining, and no heat affected zone (HAZ) was produced under the study's parameters.
研究不足
The study focused on Ti-6Al-4V workpieces fabricated by DED method and analyzed the machining characteristics by LAM. The limitations include the specific material and method used, which may not be applicable to other materials or manufacturing methods.
1:Experimental Design and Method Selection:
The study involved the development of a DED device using a metal powder feeder and a laser for fabricating Ti-6Al-4V workpieces. Thermal analysis was performed to determine the cutting depth for LAM.
2:Sample Selection and Data Sources:
Ti-6Al-4V workpieces were fabricated through many tests using the DED method.
3:List of Experimental Equipment and Materials:
A DED head (Raytools AK390TC), a diode laser (Laserline, 4 kW), a powder feeder (Metco Twin 150), and a 7-axis machine tool for LAM were used.
4:Experimental Procedures and Operational Workflow:
The cutting depth for LAM was selected through thermal analysis. LAM experiments were performed using a real-time laser power control system.
5:Data Analysis Methods:
Machining characteristics, including cutting force and surface roughness, were analyzed, and tensile test, hardness, surface analysis, and microstructural analysis were performed.
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Diode laser
LDM1000-100
Laserline
Used as a thermal energy source in the DED process.
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DED head
AK390TC
Raytools
Used in the DED additive manufacturing process for fabricating Ti-6Al-4V workpieces.
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Powder feeder
Metco Twin 150
Oerlikon
Used to transport Ti-6Al-4V powder in the DED process.
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Flat end mill
ZE322061
WIDIN Inc.
Used in the LAM process for machining Ti-6Al-4V workpieces.
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Pyrometer
LPC03
Dr. Mergenthaler GmbH & Co. KG
Used to measure and control the preheating temperature in the LAM process.
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Tool dynamometer
9257B
Kistler
Used to measure the cutting force in the LAM process.
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