Experimental investigation of selective laser melting parameters for higher surface quality and microhardness properties: taguchi and super ranking concept approaches

A Review of Simulation Tools Utilization for the Process of Laser Powder Bed Fusion

This review describes the process of metal additive manufacturing and focuses on the possibility of correlated input parameters that are important for this process. The correlation of individual parameters in the metal additive manufacturing process is considered using simulation tools that allow the prediction of various defects, thus making the real production process more efficient, especially in terms of time and costs. Special attention is paid to multiple applications using these simulation tools as an initial analysis to determine the material's behavior when defining various input factors, including the results obtained. Based on this, further procedures were implemented, including real production parts. This review also points out the range of possible variations that simulation tools have, which helps to effectively predict material defects and determine the volume of consumed material, supports construction risk, and other information necessary to obtain a quality part in the production process. From the overview of the application of simulation tools in this process, it was found that the correlation between theoretical knowledge and the definition of individual process parameters and other variables are related and are of fundamental importance for achieving the final part with the required properties. In terms of some specific findings, it can be noted that simulation tools identify adverse phenomena occurring in the production processes and allow manufacturers to test the validity of the proposed conceptual and model solutions without making actual changes in the production system, and they have the measurable impact on the design and production of quality parts.

Laser Powder Bed Fusion of Inconel 718 Tools for Cold Deep Drawing Applications: Optimization of Printing and Post-Processing Parameters

Inconel 718 (IN 718) powder is used for a laser powder bed fusion (LPBF) printer, but the mechanical properties of the as-built object are not suited to cold deep drawing applications. This study uses the Taguchi method to design experimental groups to determine the effect of various factors on the mechanical properties of as-built objects produced using an LPBF printer. The optimal printing parameters are defined using the result for the factor response to produce an as-built object with the greatest ultimate tensile strength (UTS), and this is used to produce a specimen for post-processing, including heat treatment (HT) and surface finishing. The HT parameter value that gives the maximum UTS is the optimal HT parameter. The optimal printing and HT parameter values are used to manufacture a die and a punch to verify the suitability of the manufactured tool for deep drawing applications. The experimental results show that the greatest UTS is 1091.33 MPa. The optimal printing parameters include a laser power of 190 W, a scanning speed of 600 mm/s, a hatch space of 0.105 mm and a layer thickness of 40 μm, which give a UTS of 1122.88 MPa. The UTS for the post-processed specimen increases to 1511.9 MPa. The optimal parameter values for HT are heating to 720 °C and maintaining this temperature for 8 h, decreasing the temperature to 620 °C and maintaining this temperature for 8 h, and cooling to room temperature in the furnace. Surface finishing increases the hardness to HRC 55. Tools, including a punch and a die, are manufactured using these optimized parameter values. The deep drawing experiment demonstrates that the manufactured tools that are produced using these values form a round cup of Aluminum alloy 6061. The parameter values that are defined can be used to manufacture IN 718 tools with a UTS of more than 1500 MPa and a hardness of more than 50 HRC, so these tools are suited to cold deep drawing specifications.

Minimization of Surface Roughness and Temperature during Turning of Aluminum 6061 Using Response Surface Methodology and Desirability Function Analysis

Aluminum alloy is the second most abundant metal on Earth, known for its wide range of utilization in commercial goods due to its heat capacity and tensile strength. This study examines the effect of nose radius on the turning process. Further, it explores the implications of cutting parameters such as the cutting speed, the rate of feed, the cutting depth, and the nose radius of the tool. The trials were carried out with an Al 6061 workpiece and an Al₂O₃-coated carbide tool as the cutter, utilizing the response surface methodology. A mathematical model was developed to investigate the performance characteristics of the turning operation using the analysis of variance method. The multi-response desirability function analysis combines individual desirability values to create a composite desirability value. The ideal parameter levels were determined using the composite desirability value, and the significant influence of parameters was assessed. The obtained optimum surface roughness and temperature parameters are at a cutting speed of 116.37 m/min, a rate of feed of 0.408 mm/rev, a cutting depth of 0.538 mm, and a tool nose radius of 0.20 mm. The related ideal surface roughness and temperature values are 0.374 µm and 27.439 °C. The optimal overall desirability value is 0.829, close to the target response.

Stir Casting Process Analysis and Optimization for Better Properties in Al-MWCNT-GR-Based Hybrid Composites

Pure aluminium poses inferior properties that limit its use in load-bearing applications. Reinforcing multiwall carbon nano-tube (solid lubricant) and graphene to aluminium matrix offers better (antifriction, hardness, and wear resistance) properties in composites for such applications. A stir casting processing route is employed to prepare the hybrid composite (aluminium-multiwall carbon nanotube-graphene Al-MWCNT-GR). The Taguchi L16 experimental matrix representing four variables (percent reinforcement of graphene, die temperature, melt temperature, and stir speed) operating at four levels were studied to analyze and obtain higher hardness and low wear rate in hybrid composites. Percent reinforcement of graphene showed maximum impact, and die temperature resulted with the least contribution towards both the responses. Criteria importance through intercriteria correlation (CRITIC) method is applied to determine the weight fractions (importance) for hardness and wear rate equal to 0.4752 and 0.5482, respectively. Grey relational analysis (GRA) and multi-objective optimization by the ratio analysis (MOORA) method converts multiple objective functions into a single objective function with weight fractions assigned to each output. Taguchi-CRITIC-MOORA outperformed the Taguchi-CRITIC-GRA method, which could result in 31.77% increase in hardness and a 36.33% decrease in wear rate compared to initial conditions. The optimal conditions ensure a dense microstructure with minimal pores, result in enhanced properties compared to that obtained for initial and average stir casting conditions. The worn-out surface results in a few thin and slender grooves between tracks with less crack propagation, ensuring self-lubrication in composites fabricated with the optimized condition. The better properties resulted in the hybrid composites correspond to optimized stir casting conditions and can be implemented in industries for large-scale applications.

Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.