Tan Rongkai, Zhao Xuesen, Liu Qi, Guo Xianmin, Lin Fengtao, Yang Liquan, Sun Tao
Key Laboratory of Conveyance and Equipment of Ministry of Education, East China Jiaotong University, Nanchang 330013, China.
Henan Province Engineering Research Center of Ultrasonic Technology Application, Pingdingshan University, Pingdingshan 467000, China.
Materials (Basel). 2022 Dec 13;15(24):8910. doi: 10.3390/ma15248910.
Additive manufacturing technology has been widely used in aviation, aerospace, automobiles and other fields due to the fact that near-net-shaped components with unprecedented geometric freedom can be fabricated. Additively manufactured aluminum alloy has received a lot of attention, due to its excellent material properties. However, the finished surface of additively manufactured aluminum alloy with nanoscale surface roughness is quite challenging and rarely addressed. In this paper, a novel machining technology known as ultrasonic elliptical vibration-assisted cutting (UEVC) was adopted to suppress the generation of cracks, improve the surface integrity and reduce tool wear during the ultra-precision machining of selective laser melting (SLM) additively manufactured AlSi10Mg alloy. The experimental results revealed that, in the conventional cutting (CC) process, surface defects, such as particles, pores and grooves, appeared on the machined surface, and the machined surface rapidly deteriorated with the increase in cumulative cutting area. In contrast, an almost flawless machined surface was obtained in the UEVC process, and its roughness value was less than 10 nm. Moreover, the tool wear of the CC tool was remarkably greater than that of the UEVC tool, and the standard flank wear width of the CC tool was more than twice that of the UEVC tool. Therefore, the UEVC technology is considered to be a feasible method for the ultra-precision machining of SLM additively manufactured AlSi10Mg alloy.
由于能够制造出具有前所未有的几何自由度的近净形零件，增材制造技术已在航空、航天、汽车等领域得到广泛应用。增材制造铝合金因其优异的材料性能而备受关注。然而，具有纳米级表面粗糙度的增材制造铝合金的精加工表面颇具挑战性，且很少有人涉及。本文采用一种名为超声椭圆振动辅助切削（UEVC）的新型加工技术，以抑制裂纹的产生，提高表面完整性，并减少选择性激光熔化（SLM）增材制造AlSi10Mg合金超精密加工过程中的刀具磨损。实验结果表明，在传统切削（CC）过程中，加工表面出现了颗粒、气孔和沟槽等表面缺陷，且随着累积切削面积的增加，加工表面迅速恶化。相比之下，UEVC过程获得了几乎无瑕疵的加工表面，其粗糙度值小于10 nm。此外，CC刀具的磨损明显大于UEVC刀具，CC刀具的标准后刀面磨损宽度是UEVC刀具的两倍多。因此，UEVC技术被认为是一种用于SLM增材制造AlSi10Mg合金超精密加工的可行方法。
