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Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling

  • We report on a comprehensive study to evaluate fundamental properties of a hybrid manufacturing approach, combining selective laser melting and high speed milling, and to characterize typical geometrical features and conclude on a catalogue of design rules. As for any additive manufacturing approach, the understanding of the machine properties and the process behaviour as well as such a selection guide is of upmost importance to foster the implementation of new machining concepts and support design engineers. Geometrical accuracy between digitally designed and physically realized parts made of maraging steel and dimensional limits are analyzed by stripe line projection. In particular, we identify design rules for numerous basic geometric elements like walls, cylinders, angles, inclinations, overhangs, notches, inner and outer radii of spheres, chamfers in build direction, and holes of different shape, respectively, as being manufactured by the hybrid approach and compare them to sole selective laser melting. While the cutting tool defines the manufacturability of, e.g., edges and corners, the milling itself improves the surface roughness to Ra < 2 µm. Thus, the given advantages of this hybrid process, e.g., space-resolved and custom-designed roughness and the superior geometrical accuracy are evaluated. Finally, we exemplify the potential of this particular promising hybrid approach by demonstrating an injection mold with a conformal cooling for a charge socket for an electro mobile

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Metadaten
Author:David Sommer, Babette Götzendorfer, Cemal Esen, Ralf HellmannORCiD
URL:https://www.mdpi.com/1996-1944/14/19/5753
DOI:https://doi.org/https://doi.org/10.3390/ma14195753
Parent Title (English):Design and Post Processing for Metal Additive Manufacturing
Document Type:Article
Language:English
Year of Completion:2021
Date of first Publication:2021/10/02
Release Date:2022/09/06
Tag:hybrid additive manufacturing; high-speed milling; selective laser melting; construction rules
GND Keyword:Selektives Laserschmelzen; Hochgeschwindigkeitsfräsen
Volume:14
Issue:19
First Page:1
Last Page:23
Urheberrecht:1
Institutes:Fakultät Ingenieurwissenschaften / Labore / Angewandte Lasertechnik und Photonik (alp)
research focus :Materials / Innovative Material Processing
Licence (German):Keine Lizenz - es gilt das deutsche Urheberrecht
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