Akademik Veri Yönetim Sistemi
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, sa.11-12, ss.5407-5424, 2024 (SCI-Expanded)
This study addresses machining challenges in hybrid additive manufacturing, specifically focusing on laser metal deposition on wire arc additively manufactured substrates. Under identical conditions of laser metal deposition, we identify significant differences in machinability between wire arc additively manufactured and cold-rolled substrates. Hybrid laser-wire deposition, particularly IN718 on wire arc additively manufactured steel substrate, exhibits increased cutting forces, elevated surface roughness, heightened tool wear, tool breakage, and chatter during machining attributed to increased hardness along the build direction, influenced by substrate type and thermal conductivities. To mitigate these challenges, we propose a novel heat-assisted minimum quantity lubrication (air + oil aerosol) approach. Pre-heating the material and applying minimal lubrication during machining reduces cutting forces by similar to 26%, surface roughness by similar to 60%, and tool wear by similar to 67% compared to dry machining, due to increased temperature ductility of IN718, and enhanced cooling caused by minimum quantity lubrication. These findings underscore the effectiveness of pre-heating in improving machining outcomes across diverse process parameters. Highlights Explored additive-subtractive challenges in hybrid laser metal deposition of IN718 Significantly altered machinability of HLMDed IN718 compared to LMDed counterpart Heat-assisted machining significantly enhances HLMDed IN718 machinability Substrate proximity affects machinability leading to higher forces and variability Machining outputs less sensitive to deposition conditions in heat-assisted machining