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Post-processing of powder bed fused stainless steel: micro-machining and micro-electrical discharge machining

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Abstract

Surface quality is often a specific requirement when dealing with Additive Manufacturing and dimensional accuracy, especially during 3D printing of metals. Therefore, it is crucial to evaluate the material removal behavior of Powder Bed Fusion specimens during Micro-Mechanical Machining and Micro-Electrical Discharge Machining procedures to detect their machinability responses. In this paper, micro-machining of 17-4PH stainless steel samples produced by Laser Powder Bed Fusion is reported. Specifically, we performed Micro-Mechanical Machining and Micro-Electrical Discharge Machining operations, analysed the process performances, and compared the machining conditions. Additionally, we investigated the surface roughness and burrs extension as a function of geometrical configuration and process parameters. The outcomes of this work regard the processing conditions and parameters to optimize the machining operations on 3D-printed metal samples. This work allows the identification of specific features resulting from each process in relation to the material removal rate, giving the possibility to compare and evaluate the machining conditions for 3D parts post-processing.

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Data availability

The data that support the findings of this study are not openly available due to reasons of sensitivity and are available from the corresponding author upon reasonable request. Data are located in controlled access data storage at the University of Brescia.

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Acknowledgements

Financed by the European Union—NextGenerationEU (National Sustainable Mobility Center CN00000023, Italian Ministry of University and Research Decree n. 1033-17/06/2022, Spoke 11-Innovative Materials & Lightweighting). The opinions expressed are those of the authors only and should not be considered as representative of the European Union or the European Commission’s official position. Neither the European Union nor the European Commission can be held responsible for them. CUP D83C22000690001.

Funding

Financed by Regione Lombardia (Italy), regional law no 9/2020, resolution no 3776/2020.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Brescia, Via Branze 38, 25123, Brescia, BS, Italy

    Andrea Abeni & Paola Serena Ginestra

  2. Department of Management, Information and Production Engineering, University of Bergamo, Dalmine, BG, Italy

    Mariangela Quarto

Authors
  1. Andrea Abeni
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  2. Mariangela Quarto
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  3. Paola Serena Ginestra
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Contributions

AA, MQ, PSG contributed to the study conception and design. Material preparation, data collection and analysis were performed by AA and MQ. The first draft of the manuscript was written by AA, MQ and PSG and AA, MQ, PSG commented on previous versions of the manuscript. AA, MQ, PSG read and approved the final manuscript.

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Correspondence to Andrea Abeni.

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Abeni, A., Quarto, M. & Ginestra, P.S. Post-processing of powder bed fused stainless steel: micro-machining and micro-electrical discharge machining. J Intell Manuf (2023). https://doi.org/10.1007/s10845-023-02277-z

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