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Orthogonal cutting of Wire and Arc Additive Manufactured parts

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Abstract

This work aimed to evaluate whether the established scientific knowledge for machining homogeneous and isotropic materials remains valid for machining additively manufactured parts. The machinability of thin-walled structures produced through two different variants of wire and arc additive manufacturing (WAAM) was studied, namely conventional MIG deposition and the innovative hot forging variant (HF-WAAM). Cutting operations were carried out varying the undeformed chip thickness (UCT) and the cutting speed, using a tool rake angle of 25°. A systematic comparison was made between the existing theoretical principles and the obtained practical results of the orthogonal cutting process, where the relation between the material properties (hardness, grain size, yield strength) and important machining outcomes (cutting forces, specific cutting energy, friction, shear stress, chip formation and surface roughness) is addressed. Additionally, high-speed camera records were used to evaluate the generated shear angle and chip formation process during the experimental tests. The machinability indicators shown that, through the appropriate selection of the cutting parameters, machining forces and energy consumption can be reduced up to 12%, when machining the mechanical improved additive manufactured material. Therefore, it has been confirmed the feasibility of machining such materials following the traditional machining principles, without compromising the surface quality requirements.

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taken from the centre zone of the sample produced by: a) conventional WAAM; b) HF-WAAM

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Acknowledgements

Authors would like to extend their thanks the Portuguese Military Academy Research Center (CINAMIL) for the support provided to high-speed image acquisition.

Funding

The authors acknowledge Fundação para a Ciência e a Tecnologia (FCT-MCTES) for its financial support via the project UIDB/00667/ 2020 (UNIDEMI) and by the project CARAVELA (POCI-01–0247-FEDER-039796) under the Competitiveness and Internationalization Operational Program, Regional Operational Program for Lisbon FEDER and Portugal 2020. VD acknowledges FCT-MCTES for funding the PhD grant SFRH/BD/139454/2018. TAR acknowledges FCT-MCTES for funding the PhD grant SFRH/BD/144202/2019.

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, UNIDEMI, NOVA School of Science and Technology, NOVA University Lisbon, 2829-516, Caparica, Portugal

    Pedro P. Fonseca, Catarina Vidal, Francisco Ferreira, Valdemar R. Duarte, Tiago A. Rodrigues, Telmo G. Santos & Carla M. Machado

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  1. Pedro P. Fonseca
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  2. Catarina Vidal
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  3. Francisco Ferreira
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  4. Valdemar R. Duarte
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  5. Tiago A. Rodrigues
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  7. Carla M. Machado
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Contributions

Pedro P. Fonseca contributed to conceptualization, investigation, measurement, data curation and writing and original draft preparation. Catarina Vidal wrote, reviewed and edited the manuscript. Francisco Ferreira participated in materials characterization. Valdemar R. Duarte was involved in production and characterization of the HF-WAAM samples. Tiago A. Rodrigues took part in the production of the WAAM samples. Telmo G. Santos supervised the study, and wrote, reviewed and edited the manuscript. Carla M. Machado took part in conceptualization, supervision and writing and original draft preparation.

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Correspondence to Pedro P. Fonseca.

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Fonseca, P.P., Vidal, C., Ferreira, F. et al. Orthogonal cutting of Wire and Arc Additive Manufactured parts. Int J Adv Manuf Technol 119, 4439–4459 (2022). https://doi.org/10.1007/s00170-022-08678-3

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