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The additive-subtractive process chain – a review

Moehring Hans-Christian, Maucher Clemens, Becker Dina, Stehle Thomas, Eisseler Rocco

Journal of Machine Engineering

2023

Vol. 23, No. 1

5--35

In recent years, metal additive manufacturing developed intensively and became a relevant technology in industrial production of highly complex and function integrated parts. However, almost all additively manufactured parts must be post-processed in order to fulfil geometric tolerances, surface quality demands and the desired functional properties. Thus, additive manufacturing actually means the implementation of additive-subtractive process chains. Starting with the most relevant additive processes (powder-based PBF-LB, LMD-p and wire-based WAAM and LMD-w/WLAM), considering intermediate process steps (heat treatment and shot peening) and ending up with post-processing material removal processes (with defined and undefined cutting edges), this paper gives an overview of recent research findings with respect to a comprehensive scientific investigation of influences and interactions within the additive-subtractive process chain. This includes both the macroscopic geometric scale and the microscopic scale of the material structure. Finally, conclusions and future perspectives are derived and discussed.

Influence of the support structure on the bandsawing process when separating lpbf components from the building platform

Moehring Hans-Christian, Becker Dina, Maucher Clemens, Eisseler Rocco, Ringger Jonas

Journal of Machine Engineering

2022

Vol. 22, No. 3

19--30

The method of laser powder bed fusion (LPBF) is an additive manufacturing process and allows great freedom of component geometry due to the layer-by-layer structure. The LPBF components are printed on a substrate plate and must be separated from the plate afterwards. Support structures are used to attach LPBF components to the substrate plate and to sustain overhanging parts. The cutting of the components is mainly carried out by means of a sawing process using the support structure. The forces occurring during this process are very challenging because the component has to be cut off without damage or deformation. The present study investigates and discusses the resultant forces and vibrations during the sawing of LPBF components made of titanium alloy Ti6Al4V using two different support structures. The components were arranged on the substrate plate at angles of 0°, 5°, 10°, 15°, 45° and 90° to the direction of primary motion.