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Study on tool wear during hybrid laser additive and milling subtractive manufacturing

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Abstract

Directed energy deposition (DED) technology is gaining traction in the biomedical and aviation industries due to its ability to deposit a variety of materials, create complex structures, and achieve high processing efficiency. 316L stainless steel, known for its exceptional oxidation resistance, mechanical properties, and corrosion resistance, finds extensive applications in the nuclear power sector. However, there is a dearth of literature on tool wear when machining additively manufactured alloys, especially under dry and thermal cutting conditions. These conditions are particularly relevant for hybrid additive and subtractive manufacturing (HASM), which aims to reduce clamping steps and energy consumption. Thermal milling appears to be an effective solution for streamlining the processing complexity and enhancing the bonding strength of the HASM interface. This paper aims to reduce energy consumption associated with the complex and time-consuming multi-machine tool machining process. Additionally, it seeks to evaluate the mechanisms of tool wear during the milling of DED 316L stainless steel under dry and thermal conditions using a TiAlN-coated tool at various cutting speeds. The study investigates the effects of milling temperature, number of cutting edges, and milling speed on tool wear, surface roughness, and surface residual stress. Analysis techniques such as 3D optical profilometry are employed to assess abrasive and adhesive wear. The results obtained demonstrate that cooling-free HASM can reduce clamping time and energy consumption. Quadruple-edged tools operating at 3000 r/min exhibit superior milling performance compared to double-edged tools at 2000 r/min. Furthermore, the entire tool wear process is analyzed using parameters such as Ra, Sa, and surface morphology. Examining the impact of high-temperature workpiece milling parameters on tool wear provides valuable insights for producing additive manufacturing parts with superior performance and surface quality.

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Funding

This work was supported by the National Science and Technology Major Project (2017ZX04001001), the Science Foundation of Jiangsu Province (No. BK20210758), and the China Postdoctoral Science Foundation Funded Project (No. 2022M710060).

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Authors and Affiliations

  1. Key Laboratory of CNC Equipment Reliability, Ministry of Education, School of Mechanical and Aerospace Engineering, Jilin University, Changchun, 130012, China

    Liangliang Li & Zhifeng Liu

  2. Innovation Research Institute, Shenyang Aircraft Corporation, Shenyang, 110000, China

    Liangliang Li, Xin Pan & Biao Liu

  3. School of Mechanical Engineering, Jiangsu University, Zhenjiang, 212013, China

    Pengfei Li

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  1. Liangliang Li
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  2. Xin Pan
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  3. Biao Liu
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Correspondence to Liangliang Li, Pengfei Li or Zhifeng Liu.

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Li, L., Pan, X., Liu, B. et al. Study on tool wear during hybrid laser additive and milling subtractive manufacturing. Int J Adv Manuf Technol 129, 1289–1300 (2023). https://doi.org/10.1007/s00170-023-12364-3

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