Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling
We report on a comprehensive study to evaluate fundamental properties of a hybrid manufacturing approach, combining selective laser melting and high speed milling, and to characterize typical geometrical features and conclude on a catalogue of design rules. As for any additive manufacturing approach...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-10-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/14/19/5753 |
| _version_ | 1797516061344530432 |
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| author | David Sommer Babette Götzendorfer Cemal Esen Ralf Hellmann |
| author_facet | David Sommer Babette Götzendorfer Cemal Esen Ralf Hellmann |
| author_sort | David Sommer |
| collection | DOAJ |
| description | We report on a comprehensive study to evaluate fundamental properties of a hybrid manufacturing approach, combining selective laser melting and high speed milling, and to characterize typical geometrical features and conclude on a catalogue of design rules. As for any additive manufacturing approach, the understanding of the machine properties and the process behaviour as well as such a selection guide is of upmost importance to foster the implementation of new machining concepts and support design engineers. Geometrical accuracy between digitally designed and physically realized parts made of maraging steel and dimensional limits are analyzed by stripe line projection. In particular, we identify design rules for numerous basic geometric elements like walls, cylinders, angles, inclinations, overhangs, notches, inner and outer radii of spheres, chamfers in build direction, and holes of different shape, respectively, as being manufactured by the hybrid approach and compare them to sole selective laser melting. While the cutting tool defines the manufacturability of, e.g., edges and corners, the milling itself improves the surface roughness to Ra < 2<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mspace width="0.166667em"></mspace><mi mathvariant="sans-serif">μ</mi></mrow></semantics></math></inline-formula>m. Thus, the given advantages of this hybrid process, e.g., space-resolved and custom-designed roughness and the superior geometrical accuracy are evaluated. Finally, we exemplify the potential of this particular promising hybrid approach by demonstrating an injection mold with a conformal cooling for a charge socket for an electro mobile. |
| first_indexed | 2024-03-10T06:56:03Z |
| format | Article |
| id | doaj.art-76a1b372c8c446e29991bb1c78daa982 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T06:56:03Z |
| publishDate | 2021-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-76a1b372c8c446e29991bb1c78daa9822023-11-22T16:26:38ZengMDPI AGMaterials1996-19442021-10-011419575310.3390/ma14195753Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and MicromillingDavid Sommer0Babette Götzendorfer1Cemal Esen2Ralf Hellmann3Applied Laser and Photonics Group, University of Applied Sciences Aschaffenburg, 63743 Aschaffenburg, GermanyApplied Laser and Photonics Group, University of Applied Sciences Aschaffenburg, 63743 Aschaffenburg, GermanyApplied Laser Technologies, Ruhr-University Bochum, 44801 Bochum, GermanyApplied Laser and Photonics Group, University of Applied Sciences Aschaffenburg, 63743 Aschaffenburg, GermanyWe report on a comprehensive study to evaluate fundamental properties of a hybrid manufacturing approach, combining selective laser melting and high speed milling, and to characterize typical geometrical features and conclude on a catalogue of design rules. As for any additive manufacturing approach, the understanding of the machine properties and the process behaviour as well as such a selection guide is of upmost importance to foster the implementation of new machining concepts and support design engineers. Geometrical accuracy between digitally designed and physically realized parts made of maraging steel and dimensional limits are analyzed by stripe line projection. In particular, we identify design rules for numerous basic geometric elements like walls, cylinders, angles, inclinations, overhangs, notches, inner and outer radii of spheres, chamfers in build direction, and holes of different shape, respectively, as being manufactured by the hybrid approach and compare them to sole selective laser melting. While the cutting tool defines the manufacturability of, e.g., edges and corners, the milling itself improves the surface roughness to Ra < 2<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mspace width="0.166667em"></mspace><mi mathvariant="sans-serif">μ</mi></mrow></semantics></math></inline-formula>m. Thus, the given advantages of this hybrid process, e.g., space-resolved and custom-designed roughness and the superior geometrical accuracy are evaluated. Finally, we exemplify the potential of this particular promising hybrid approach by demonstrating an injection mold with a conformal cooling for a charge socket for an electro mobile.https://www.mdpi.com/1996-1944/14/19/5753hybrid additive manufacturinghigh-speed millingselective laser meltingconstruction rules |
| spellingShingle | David Sommer Babette Götzendorfer Cemal Esen Ralf Hellmann Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling Materials hybrid additive manufacturing high-speed milling selective laser melting construction rules |
| title | Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling |
| title_full | Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling |
| title_fullStr | Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling |
| title_full_unstemmed | Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling |
| title_short | Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling |
| title_sort | design rules for hybrid additive manufacturing combining selective laser melting and micromilling |
| topic | hybrid additive manufacturing high-speed milling selective laser melting construction rules |
| url | https://www.mdpi.com/1996-1944/14/19/5753 |
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