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Investigation and process optimization for magnetic abrasive finishing additive manufacturing samples with different forming angles

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Abstract

The staircase effect, balling effect, and powder adhesion as well as other problems in additive manufacturing (AM) forming all lead to the poor uniformity and high roughness of the sample surfaces. Therefore, there exist differences in the physical and mechanical properties of the samples. In this paper, the spherical composite magnetic abrasive particles (MAPs) are used for magnetic abrasive finishing (MAF) experimental investigations and process optimization of the AM sample surface. According to the Box-Behnken design principle of the response surface methodology, the finishing effects of different process parameters (spindle speed, feed speed, and machining gap) of MAF on the samples prepared by selective laser melting (SLM) with different formed angles are studied, the quadratic regression equations are established, and the validity of the equations are assessed by ANOVA and 3D response surfaces. After that, MAPs with smaller size were selected for the fine MAF experiments with the optimized parameters. Finally, we found that the optimal parameters of MAF for the same material with different forming angles are similar, but the polishing time consumed is quite different. After the MAF experiments, the changes of the surface Vickers hardness, roughness (Ra), and microscopic morphology are analyzed. The surface roughness of each sample is reduced from the initial 4–10 μm to about 100 nm, and the diversities in hardness are also reduced. MAF significantly improves the defects of poor surface uniformity caused by inconsistent forming angles.

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Funding

This work is supported by the National Natural Science Foundation of China (No. 51675316).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University of Technology, Zibo, 255000, China

    Peixin Zhu, Guixiang Zhang, Xiao Teng, Jiajing Du, Linzhi Jiang, Haoxin Chen & Ning Liu

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  1. Peixin Zhu
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  2. Guixiang Zhang
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  3. Xiao Teng
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  4. Jiajing Du
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Contributions

Peixin Zhu contributed to the investigation, conduction of SLM and MAF experiments and writing of the original draft, writing of the review, and editing.

Guixiang Zhang contributed to the writing of the review, editing, and funding acquisition.

Xiao Teng contributed to the conduction of the SLM experiment and writing of the review, and editing.

Jiajing Du, Linzhi Jiang, Haoxin Chen, and Ning Liu contributed to the review and editing with the order provided.

Corresponding author

Correspondence to Guixiang Zhang.

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The authors declare no competing interests.

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Appendix

Appendix

Table 6 ANOVA results for optimization of SLM samples with MAF
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Table 7 Diagnosis of model reliability
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Table 8 The interactive effect of spindle speed (A), feed rate (B), and machining gap (C)
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Zhu, P., Zhang, G., Teng, X. et al. Investigation and process optimization for magnetic abrasive finishing additive manufacturing samples with different forming angles. Int J Adv Manuf Technol 118, 2355–2371 (2022). https://doi.org/10.1007/s00170-021-08083-2

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