Medibew Tesfaye Mengesha, Zieliński Dawid, Agebo Sisay Workineh, Deja Mariusz
Doctoral School, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdansk, Poland.
Department of Manufacturing and Production Engineering, Institute of Machine and Materials Technology, Faculty of Mechanical Engineering and Ship Technology, Gdańsk University of Technology, Gabriela Narutowicza Street 11/12, 80-233 Gdansk, Poland.
Materials (Basel). 2025 Mar 12;18(6):1249. doi: 10.3390/ma18061249.
Additive manufacturing (AM) has revolutionized the production of complex geometrical parts with metals; however, the usual layer-by-layer deposition results in poor surface quality and unpredictable surface integrity. Abrasive machining and finishing techniques play vital roles in counteracting these challenges and qualifying AM parts for practical applications. This review aims to present recent research developments concerning the machining of additively manufactured metal parts via both conventional and nonconventional abrasive machining methods. Conventional methods such as grinding, milling, polishing, honing, and sandblasting have been widely investigated for their ability to enhance the surface finish, dimensional accuracy, and mechanical properties of AM metal components. However, the characteristic features of various AM processes, such as porosity, microstructural features, and residual stresses, can significantly influence the machinability of the produced parts. Nonconventional methods such as abrasive flow machining, electrochemical machining, magnetic abrasive finishing, and vibratory bowl finishing, on the other hand, have shown potential in addressing the difficulties associated with internal machining geometries and hard-to-machine material combinations that are typical for many AM parts. This review also highlights some challenges and future trends in the machining of AM metal parts and emphasizes that further research is required in the direction of combinations of various postprocessing techniques, machinability regarding new alloy compositions, and the integration of AI for process optimization. As the demand for high-precision AM parts grows across various industries, the advancement of abrasive machining and finishing techniques is crucial for driving the wider adoption of AM technologies.
增材制造（AM）彻底改变了金属复杂几何零件的生产方式；然而，通常的逐层沉积会导致表面质量差和表面完整性不可预测。研磨加工和精加工技术在应对这些挑战以及使增材制造零件符合实际应用要求方面发挥着至关重要的作用。本综述旨在介绍通过传统和非传统研磨加工方法对增材制造金属零件进行加工的最新研究进展。诸如磨削、铣削、抛光、珩磨和喷砂等传统方法，因其能够提高增材制造金属部件的表面光洁度、尺寸精度和机械性能而得到了广泛研究。然而，各种增材制造工艺的特征，如孔隙率、微观结构特征和残余应力，会显著影响所生产零件的可加工性。另一方面，诸如磨料流加工、电化学加工、磁性研磨精加工和振动盘式精加工等非传统方法，在解决许多增材制造零件典型的内部加工几何形状和难加工材料组合相关难题方面已显示出潜力。本综述还强调了增材制造金属零件加工中的一些挑战和未来趋势，并强调在各种后处理技术的组合、新合金成分的可加工性以及用于工艺优化的人工智能集成方向上还需要进一步研究。随着各行业对高精度增材制造零件的需求不断增长，研磨加工和精加工技术的进步对于推动增材制造技术的更广泛应用至关重要。
