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Investigation of manufacturability and efficiency of micro channels with different geometries produced by direct metal laser sintering

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Abstract

Manufacturability without supports in design studies for additive manufacturing (AM) brings many advantages such as time, cost, part surface quality, and design freedom. It is thought that the geometries that can be produced without support will help the more widespread use of AM technologies. In this study, the unsupported manufacturability and efficiency research of conformal cooling channel (CCC) geometries created in cylindrical, wide oval, drop, hexagonal, narrow oval, and pentagonal cross-sections were conducted in the direct metal laser sintering (DMLS) system. The study offers innovation in terms of showing the usability of different channel geometries in CCC applications. The study shows that the pentagon form has the most efficient cooling capacity among the comparatively handled geometries. The results are obtained by a computational fluid dynamics (CFD) analysis study on computer-aided design (CAD) data of the actual state channel geometry obtained by CAD and post-production micro-CT scanning of the design and presented in tables. This research shows that the production-induced sagging problem affects the flow by narrowing the channel hydraulic diameter in channel geometries produced without CCC supports.

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Funding

This study was prepared within the scope of “ALUTEAM-Aluminum Test Training and Research Center,” carried out by Fatih Sultan Mehmet Vakif University.

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Authors and Affiliations

  1. Aluminium Test, Training and Research Center (ALUTEAM), Fatih Sultan Mehmet Vakif University, TR 34445, Halic Campus, Beyoglu, Istanbul, Turkey

    Cemal İrfan Çalışkan, Mert Coşkun, Gökhan Özer & Ebubekir Koç

  2. Karfo Endüstriyel, Karfo Plaza, TR 34775, Y. Dudullu, Umraniye, Istanbul, Turkey

    Turgut Azer Vurkır & Gökay Yöndem

Authors
  1. Cemal İrfan Çalışkan
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  2. Mert Coşkun
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  3. Gökhan Özer
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  4. Ebubekir Koç
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  5. Turgut Azer Vurkır
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  6. Gökay Yöndem
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Contributions

Cemal İrfan Çalışkan: The design process and DMLS production section authorship, product development and CAD modeling, table studies; Mert Coşkun: Flow analysis and numerical modeling and DMLS workshop; Dr. Gökhan Özer, literature authorship, laboratory work organization, editorial, and translation; Dr. Ebubekir Koç, coordinator; Azer Vurkır and Gökay Yöndem: micro-CT studies.

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Correspondence to Cemal İrfan Çalışkan.

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Çalışkan, C.İ., Coşkun, M., Özer, G. et al. Investigation of manufacturability and efficiency of micro channels with different geometries produced by direct metal laser sintering. Int J Adv Manuf Technol 117, 3805–3817 (2021). https://doi.org/10.1007/s00170-021-07928-0

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