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Study of tool wear in milling process of wire and arc additive manufactured parts
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Orientador(es)
Resumo(s)
A manufatura aditiva é atualmente um dos principais assuntos em destaque no mundo da engenharia.
Avanços científicos recentes mostram que as tecnologias de manufatura aditiva baseadas em processos
de arco elétrico têm um grande potencial industrial e podem realmente melhorar a forma como os
componentes metálicos de grandes dimensões e de forma complexa são fabricados.
Apesar de todas as vantagens que a tecnologia WAAM apresenta, algumas características inerentes a
este processo devem ser consideradas para que uma implementação bem-sucedida na indústria seja
alcançada. Na maior parte das vezes, defeitos como a baixa qualidade superficial e o aparecimento de
distorções devido aos ciclos térmicos só podem ser eliminados com o uso de operações de pós-
processamento como maquinagem CNC, permitindo que as imperfeições geométricas sejam
eliminadas e que as peças produzidas cumpram as especificações exigidas. No entanto, a anisotropia
das peças produzidas influencia fortemente o desempenho das ferramentas de corte durante as
operações de maquinagem, revelando diferentes mecanismos de desgaste consoante a zona a ser
maquinada.
Nesta investigação foram produzidas peças de parede fina por WAAM e foi avaliado o desgaste
durante as operações de maquinagem sob condições de lubrificação em quantidade mínima e
maquinagem a seco tendo como base a medição experimental do valor de desgaste de flanco, das forças
de corte e da rugosidade superficial. O sistema de lubrificação mínima utilizado foi também projetado
e produzido no âmbito desta investigação.
Os resultados obtidos revelam diferenças notáveis no desempenho da ferramenta de corte entre as
diferentes zonas das peças fabricadas. Adicionalmente, foram observados diferentes valores de vida
útil da ferramenta quando comparando peças de alta entrega térmica com baixa entrega térmica.
Additive manufacturing is currently one of the hot topics in the manufacturing and engineering world. Recent scientific advances show that the arc-based additive technologies have a serious industrial potential and can really improve how large complex-shaped metallic components are manufactured. Despite the advantages that WAAM exhibits, some inherent characteristics of this process need to be accounted for so that a successful implementation in the industry is achieved. Low surface quality and residual stresses bringing geometrical inaccuracy can only be surpassed with the use of post-processing operations like CNC machining, allowing the produced parts to meet the required specifications. However, the anisotropy of the produced parts strongly influences the milling performance of the cutting tools, resulting in a different wear evolution according to the region to be machined. In this investigation, thin-walled parts were produced and the wear performance under MQL and dry machining conditions was evaluated based on experimental measurement of the flank wear value, the cutting forces and also the surface roughness. The acquired results reveal some performance differences between the base, mid ant top region of the manufactured parts where different wear rates were observed. Different values of tool life were also measured when comparing high heat input with low heat input samples, as a consequence of the different material properties.
Additive manufacturing is currently one of the hot topics in the manufacturing and engineering world. Recent scientific advances show that the arc-based additive technologies have a serious industrial potential and can really improve how large complex-shaped metallic components are manufactured. Despite the advantages that WAAM exhibits, some inherent characteristics of this process need to be accounted for so that a successful implementation in the industry is achieved. Low surface quality and residual stresses bringing geometrical inaccuracy can only be surpassed with the use of post-processing operations like CNC machining, allowing the produced parts to meet the required specifications. However, the anisotropy of the produced parts strongly influences the milling performance of the cutting tools, resulting in a different wear evolution according to the region to be machined. In this investigation, thin-walled parts were produced and the wear performance under MQL and dry machining conditions was evaluated based on experimental measurement of the flank wear value, the cutting forces and also the surface roughness. The acquired results reveal some performance differences between the base, mid ant top region of the manufactured parts where different wear rates were observed. Different values of tool life were also measured when comparing high heat input with low heat input samples, as a consequence of the different material properties.
Descrição
Palavras-chave
Additive manufacturing WAAM HSLA Milling Tool wear