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A comparative study of dry and cryogenic milling for Directed Energy Deposited IN718 components: effect on process and part quality

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Abstract

The integration of machining as a post-processing method for additive manufacturing (AM) can promote the industrialization of AM and enable it to meet the requirements of high-value industries. This integration introduces several challenges for the machining process, which are related to process design and planning. A major aspect that requires investigation is the cooling of the machining process. Effective cooling is a key part of the machining process, especially when hard materials with low machinability are involved, which is the case with parts built by AM. However, oil-based coolants cannot be utilized in the context of hybrid manufacturing because they contaminate the surface of the part that can lead to the introduction of defects in a successive AM process. Cryogenic cooling is a high-performance and sustainable cooling approach that can be employed to overcome this issue, since it provides a clean surface after the machining process. Although cryogenic cooling is a very promising and sustainable alternative for high-performance cooling, most studies only investigate limited benefits that it can provide in the machining process. Therefore, this paper aims to provide a full overview of the effect of cryogenic cooling with liquid nitrogen (LN2) during milling of Directed Energy Deposited IN718 samples, examining the cutting forces, tool wear, surface roughness and residual stresses on the machined components. The results prove that cryogenic cooling can reduce significantly the cutting forces and tool wear, while its impact on the surface roughness is limited.

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Abbreviations

AM:

Additive Manufacturing

ADoC:

Axial depth of cut

CMOS:

Complementary Metal oxide semiconductor

DED:

Directed Energy Deposition

EBM:

Electron Beam Melting

HDM:

Hole-drilling strain-gage method

HRA:

Heat-resistant alloy

LCO2 :

Liquid carbon dioxide

LMD:

Laser Metal Deposition

LN2 :

Liquid nitrogen

MQL:

Minimum Quantity Lubrication

PVD:

Physical Vapor Deposition

RDoC:

Radial depth of cut

\({{\varvec{f}}}_{{\varvec{z}}}\) :

Feed per tooth [mm]

\({\varvec{h}}\) :

Undeformed chip thickness

\({{\varvec{h}}}_{{\varvec{c}}}\) :

Deformed chip thickness

\({{\varvec{K}}}_{{\varvec{t}}{\varvec{c}}},\boldsymbol{ }{{\varvec{K}}}_{{\varvec{r}}{\varvec{c}}},\boldsymbol{ }{{\varvec{K}}}_{{\varvec{a}}{\varvec{c}}}\) :

Cutting force coefficients in the tangential, radial, and axial direction [N/mm2]

\({{\varvec{K}}}_{{\varvec{t}}{\varvec{e}}},\boldsymbol{ }{{\varvec{K}}}_{{\varvec{r}}{\varvec{e}}},\boldsymbol{ }{{\varvec{K}}}_{{\varvec{a}}{\varvec{e}}}\) :

Edge force coefficients in the tangential, radial, and axial direction [N/mm]

\({{\varvec{r}}}_{{\varvec{C}}}\) :

Chip compression ratio

\({{\varvec{v}}}_{{\varvec{C}}}\) :

Cutting speed [m/min]

\({\boldsymbol{\varphi }}_{{\varvec{C}}}\) :

Shear angle [rad]

\({\boldsymbol{\varphi }}_{{\varvec{j}}}\) :

Immersion angle of jth cutting edge [rad]

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Acknowledgements

This research has been partially funded by EIT Manufacturing, under the 2020 activity “FlexHyMan: A Flexible Hybrid Manufacturing system,” A20117 and by the European Regional Development Fund of the European Union and Greek national funds through the Operational Program Competitiveness, Entrepreneurship and Innovation, under the call RESEARCH – CREATE – INNOVATE (project code: T2EDK – 03896).

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Authors and Affiliations

  1. Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, 265 04, Patras, Greece

    Thanassis Souflas, Harry Bikas & Panagiotis Stavropoulos

  2. Comau France, Rue de l’Industrie, 81100, Castres, France

    Mani Ghassempouri

  3. Department of Management and Production Engineering (DIGEP), Politecnico di Torino, C.so Duca degli Abruzzi, 24, 10129, Torino, Italy

    Alessandro Salmi, Eleonora Atzeni & Abdollah Saboori

  4. Department of Innovative Technologies, University of Applied Science and Arts of Southern Switzerland (SUPSI), Via La Santa 1, 6962, Lugano, Switzerland

    Ivan Brugnetti, Anna Valente & Federico Mazzucato

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  1. Thanassis Souflas
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Contributions

Thanassis Souflas: formal analysis, methodology, visualization, writing -original draft; Harry Bikas: formal analysis, methodology, visualization, writing -original draft; Mani Ghassempouri: formal analysis, methodology, visualization, writing -original draft; Alessandro Salmi: formal analysis, methodology, visualization, writing -original draft; Eleonora Atzeni: formal analysis, methodology, visualization, writing -original draft; Abdollah Saboori: conceptualization, funding acquisition, methodology, writing- review and editing; Ivan Brugnetti: formal analysis, methodology, visualization, Writing -original draft; Anna Valente: conceptualization, funding acquisition, methodology, writing- review and editing; Federico Mazzucato: formal analysis, methodology, visualization, writing -original draft; Panagiotis Stavropoulos: conceptualization, funding acquisition, methodology, project administration, resources, writing- review and editing.

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Correspondence to Panagiotis Stavropoulos.

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Souflas, T., Bikas, H., Ghassempouri, M. et al. A comparative study of dry and cryogenic milling for Directed Energy Deposited IN718 components: effect on process and part quality. Int J Adv Manuf Technol 119, 745–758 (2022). https://doi.org/10.1007/s00170-021-08313-7

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