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An integrated macroscopic model for simulating SLM and milling processes

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Abstract

Due to their flexibility to also build up highly complex geometries, Additive Manufacturing (AM) processes are increasingly applied. Although near net-shape components can be manufactured using, for example, the Selective Laser Melting (SLM) process, the required surface quality can often not be achieved. In order to manufacture contact areas or functional surfaces, subsequent machining processes can be used to achieve the required accuracy in shape and dimension as well as the desired surface quality. In order to reduce the experimental effort during process design and optimization, simulation systems that are able to efficiently model both processes are required. In this paper, an empirical geometry-based model for SLM and milling processes will be presented. Due to the usage of an empirical model, based on the analysis of a set of reference structures, the simulation of macroscopic geometries can be achieved and used in subsequent milling simulations. Furthermore, an experimental validation of the combination of the two simulation models will be presented.

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Acknowledgements

The authors would like to thank K. Geenen, A. Röttger and W. Theisen from the Chair of Materials Technology (LWT, RUB) for providing the specimens for the slot milling tests and the SLM Solutions Group AG for manufacturing the test workpiece.

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Authors and Affiliations

  1. Virtual Machining, TU Dortmund University, Dortmund, Germany

    Petra Wiederkehr & Jim A. Bergmann

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  1. Petra Wiederkehr
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  2. Jim A. Bergmann
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Correspondence to Petra Wiederkehr.

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Wiederkehr, P., Bergmann, J.A. An integrated macroscopic model for simulating SLM and milling processes. Prod. Eng. Res. Devel. 12, 465–472 (2018). https://doi.org/10.1007/s11740-018-0822-3

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  • DOI: https://doi.org/10.1007/s11740-018-0822-3

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