Title: Grinding investigations of Ti-6Al-4V parts produced using direct metal laser sintering technology

Authors: Anil K. Srivastava; Radu Pavel

Addresses: Manufacturing Engineering Department, The University of Texas – Pan American, 1201 West University Dr., Edinburg, TX 78539, USA ' TechSolve, Inc., 6705 Steger Drive, Cincinnati, OH 45237, USA

Abstract: The effect of various grinding parameters on the surface integrity of titanium (Ti-6Al-4V) alloy specimens produced using direct metal laser sintering (DMLS^®) process have been studied. The goal has been to identify the safe grinding parameters that would result in ground surfaces free of defects such as micro-cracks, discoloration, and/or burn marks which occur due to localised high heat generated during grinding. The residual stresses have been used to quantify the effect of grinding parameters on the ground surface. The experimental results show that the grinding parameters within the range of 10.2 m/s-20.3 m/s wheel speed, 12.2 m/min-14.7 m/min feed rate, and a depth of cut smaller than 0.025 mm, with the condition that any of the combination of these parameters leading to an equivalent chip thickness lower than 0.254 µm, and a specific material removal rate lower than 4.3 mm³/s/mm will provide compressive residual stresses and can be used as safe grinding parameters.

Keywords: direct metal laser sintering; DMLS; dressing in-feed; equivalent chip thickness; grinding forces; grinding power; surface integrity; residual stress; microcracks; discoloration; burn marks; surface roughness; microstructure; surface quality; titanium alloys; material removal rate; MRR.

DOI: 10.1504/IJMMS.2015.073566

International Journal of Mechatronics and Manufacturing Systems, 2015 Vol.8 No.5/6, pp.223 - 242

Received: 04 May 2015
Accepted: 14 Jul 2015
Published online: 12 Dec 2015 *

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