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Consideration of additive manufacturing supports for post-processing by end milling: a hybrid analytical–numerical model and experimental validation

Abstract : Finishing operations of parts produced by additive manufacturing are nowadays an important challenge in this field. To obtain a functional part, certain surfaces require post-processing by machining operations. In this study, an innovative approach is developed using the manufacturing supports as a clamping device for the milling operation. This approach saves time and operations in the overall value chain to obtain a finished part. To achieve this goal, the effects on the machining operation of the heterogeneous flexibility of the assembly composed of the part and its supports have to be analyzed. The present study aims to propose a model combining an analytical approach to determine the cutting forces with a finite element model (FEM) to predict the dynamical response of the workpiece-supports system. The effect of the workpiece displacements on the material removal by the tool is taken into account. The mechanical loading on the workpiece, due to the cutting forces, is introduced in the FEM through a user subroutine provided by ABAQUS/standard. To reduce the calculation time, a homogenization procedure is used by replacing the complex structure of the supports with a simplified geometry with equivalent stiffness and mechanical properties. To validate the proposed approach, end milling tests were performed on Ti6Al4V parts produced by SLM additive manufacturing. In general, the comparison between the experiment and the model shows a match of the cutting force signals for the rigid and flexible samples. From this study, it appears that the present approach can be used to validate the design of additive manufacturing supports as a machining device and to optimize cutting conditions to reduce machining vibrations.
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https://hal.univ-lorraine.fr/hal-03606326
Contributor : Pascal Laheurte Connect in order to contact the contributor
Submitted on : Friday, March 11, 2022 - 4:56:04 PM
Last modification on : Friday, April 8, 2022 - 12:53:37 PM

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P. Didier, G. Le Coz, G. Robin, P. Lohmuller, B. Piotrowski, et al.. Consideration of additive manufacturing supports for post-processing by end milling: a hybrid analytical–numerical model and experimental validation. Progress in Additive Manufacturing, Springer Verlag, 2022, 7 (1), pp.15-27. ⟨10.1007/s40964-021-00211-4⟩. ⟨hal-03606326⟩

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