Hostname: page-component-cd9895bd7-gbm5v Total loading time: 0 Render date: 2024-12-26T21:44:13.685Z Has data issue: false hasContentIssue false

Surface Roughness and Design for Additive Manufacturing: A Design Artefact Investigation

Published online by Cambridge University Press:  26 May 2022

D. Obilanade*
Affiliation:
Luleå University of Technology, Sweden
P. Törlind
Affiliation:
Luleå University of Technology, Sweden
C. Dordlofva
Affiliation:
Luleå University of Technology, Sweden GKN Aerospace Engine Systems, Sweden

Abstract

Core share and HTML view are not available for this content. However, as you have access to this content, a full PDF is available via the ‘Save PDF’ action button.

Laser Powder Bed Fusion (LPBF) brings the possibility to manufacture innovative near-net-shape part designs. But unfortunately, some designed surfaces suffer from rough surface finish due to characteristics of the LPBF process. This paper explores trends in managing surface roughness and through a space industry case study, a proposed process that uses Additive Manufacturing Design Artefacts (AMDAs) is used to investigate the relationship between design, surface roughness and fatigue. The process enables the identification of design uncertainties, however, iterations of AMDA's can be required.

Type
Article
Creative Commons
Creative Common License - CCCreative Common License - BYCreative Common License - NCCreative Common License - ND
This is an Open Access article, distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives licence (http://creativecommons.org/licenses/by-nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is unaltered and is properly cited. The written permission of Cambridge University Press must be obtained for commercial re-use or in order to create a derivative work.
Copyright
The Author(s), 2022.

References

Ahn, D., Kim, H., Lee, S., 2007. Fabrication direction optimization to minimize post-machining in layered manufacturing. International Journal of Machine Tools and Manufacture 47, 593606. 10.1016/j.ijmachtools.2006.05.004Google Scholar
ASTM, 2002. Standard Practice for Conducting Force Controlled Constant Amplitude Axial Fatigue Tests of Metallic Materials. Test 03.Google Scholar
Atkinson, H. v., Davies, S., 2000. Fundamental aspects of hot isostatic pressing: An overview. Metallurgical and Materials Transactions A 2000 31:12 31, 2981–3000. 10.1007/S11661-000-0078-2Google Scholar
Borgue, O., Panarotto, M., Isaksson, O., 2019. Modular product design for additive manufacturing of satellite components: maximising product value using genetic algorithms. Concurrent Engineering Research and Applications 27, 331346. 10.1177/1063293X19883421Google Scholar
Cooper, R.G., 2014. What's next? After stage-gate. Research Technology Management 57, 2031. 10.5437/08956308X5606963Google Scholar
Dordlofva, C., Törlind, P., 2020. Evaluating design uncertainties in additive manufacturing using design artefacts: examples from space industry. Design Science 6, e12. 10.1017/dsj.2020.11CrossRefGoogle Scholar
du Plessis, A., Beretta, S., 2020. Killer notches: The effect of as-built surface roughness on fatigue failure in AlSi10Mg produced by laser powder bed fusion. Additive Manufacturing 35. 10.1016/j.addma.2020.101424CrossRefGoogle Scholar
Feng, S., Chen, S., Kamat, A.M., Zhang, R., Huang, M., Hu, L., 2020. Investigation on shape deviation of horizontal interior circular channels fabricated by laser powder bed fusion. Additive Manufacturing 36, 101585. 10.1016/J.ADDMA.2020.101585Google Scholar
Gibson, I., Rosen, D., Stucker, B., 2015. Additive manufacturing technologies: 3D printing, rapid prototyping, and direct digital manufacturing, second edition, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, Second Edition. 10.1007/978-1-4939-2113-3Google Scholar
ISO/ASTM 52911-1-19, 2019. Additive manufacturing — Design — Part 1: Laser-based powder bed fusion of metals, ASTM International.Google Scholar
ISO/ASTM TC261, 2018. ISO/ASTM/DIS 52902, Additive manufacturing, Test artificats, Standard guideline for geometric capability assessment of additive manufacturing systems, ISO/ASTM TC261.Google Scholar
Jones, A., Leary, M., Bateman, S., Easton, M., 2021. Effect of surface geometry on laser powder bed fusion defects. Journal of Materials Processing Technology 296, 117179. 10.1016/j.jmatprotec.2021.117179CrossRefGoogle Scholar
Klingaa, C.G., Mohanty, S., Hattel, J.H., 2020. Realistic design of laser powder bed fusion channels. Rapid Prototyping Journal 26, 18271836. 10.1108/RPJ-01-2020-0010CrossRefGoogle Scholar
Kokkonen, P., Salonen, L., Virta, J., Hemming, B., Laukkanen, P., Savolainen, M., 2016. Design guide for additive manufacturing of metal components by SLM process. Digital Open Access Repository of VTT 131.Google Scholar
Masuo, H., Tanaka, Y., Morokoshi, S., Yagura, H., Uchida, T., Yamamoto, Y., Murakami, Y., 2018. Influence of defects, surface roughness and HIP on the fatigue strength of Ti-6Al-4V manufactured by additive manufacturing. International Journal of Fatigue 117, 163179. 10.1016/J.IJFATIGUE.2018.07.020Google Scholar
Menold, J., Jablokow, K., Simpson, T., 2017. Prototype for X (PFX): A holistic framework for structuring prototyping methods to support engineering design. Design Studies 50, 70112. 10.1016/J.DESTUD.2017.03.001Google Scholar
Nicoletto, G., Konečna, R., Frkan, M., Riva, E., 2020. Influence of layer-wise fabrication and surface orientation on the notch fatigue behavior of as-built additively manufactured Ti6Al4V. International Journal of Fatigue 134. 10.1016/j.ijfatigue.2020.105483CrossRefGoogle Scholar
Nicoletto, G., Konečná, R., Kunz, L., Frkáň, M., 2018. Influence of as-built surface on fatigue strength and notch sensitivity of Ti6Al4V alloy produced by DMLS, in: MATEC Web of Conferences. 10.1051/matecconf/201816502002Google Scholar
Obilanade, D., Dordlofva, C., Törlind, P., 2021. Surface roughness considerations in design for additive manufacturing - a literature review. Proceedings of the Design Society 1, 28412850. 10.1017/pds.2021.545CrossRefGoogle Scholar
Overton, G., 2017. 3D metal AM allows 100-to-1 parts reduction for satellite maker OptiSys | Laser Focus World [WWW Document]. Laser Focus World. URL https://www.laserfocusworld.com/lasers-sources/article/16569481/3d-metal-am-allows-100to1-parts-reduction-for-satellite-maker-optisys (accessed 11.6.21).Google Scholar
Azar A, S., Reiersen, M., Hovig, E.W., M'hamdi, M., Diplas, S., Pedersen, M.M., 2021. A novel approach for enhancing the fatigue lifetime of the components processed by additive manufacturing technologies. Rapid Prototyping Journal 27, 256267. 10.1108/RPJ-02-2020-0030Google Scholar
Svensson, L., Brulin, G., Ellström, P.E., 2015. Interactive research and ongoing evaluation as joint learning processes, in: Sustainable Development in Organizations: Studies on Innovative Practices. 10.4337/9781784716899.00024Google Scholar
Tang, Y., Zhao, Y.F., 2016. A survey of the design methods for additive manufacturing to improve functional performance. Rapid Prototyping Journal 22, 569590. 10.1108/RPJ-01-2015-0011CrossRefGoogle Scholar
Wycisk, E., Solbach, A., Siddique, S., Herzog, D., Walther, F., Emmelmann, C., 2014. Effects of defects in laser additive manufactured Ti-6Al-4V on fatigue properties. Physics Procedia 56, 371378. 10.1016/J.PHPRO.2014.08.120CrossRefGoogle Scholar
Yadollahi, A., Shamsaei, N., 2017. Additive manufacturing of fatigue resistant materials: Challenges and opportunities. International Journal of Fatigue 98, 1431. 10.1016/J.IJFATIGUE.2017.01.001Google Scholar
Yang, S., Zhao, Y.F., 2018. Additive Manufacturing-Enabled Part Count Reduction: A Lifecycle Perspective. Journal of Mechanical Design, Transactions of the ASME 140. 10.1115/1.4038922CrossRefGoogle Scholar
Zhou, L., Zhu, Y., Liu, H., He, T., Zhang, C., Yang, H., 2021. A comprehensive model to predict friction factors of fluid channels fabricated using laser powder bed fusion additive manufacturing. Additive Manufacturing 47, 102212. 10.1016/j.addma.2021.102212Google Scholar
Zhou, L., Zhu, Y., Yang, H., 2020. A New Friction Factor Calculation Model and Design Approach of Flow Channels Based on Additive Manufacturing, in: BATH/ASME 2020 Symposium on Fluid Power and Motion Control. American Society of Mechanical Engineers. 10.1115/FPMC2020-2723Google Scholar