Please use this identifier to cite or link to this item: https://doi.org/10.1016/j.jmatprotec.2020.116597
Title: Optical surface generation on additively manufactured AlSiMg0.75 alloys with ultrasonic vibration-assisted machining
Authors: Bai, Yuchao
Shi, Zhuoqi
Lee, Yan Jin
Wang, Hao 
Keywords: Science & Technology
Technology
Engineering, Industrial
Engineering, Manufacturing
Materials Science, Multidisciplinary
Engineering
Materials Science
Selective laser melting
Ultraprecision machining
Vibration-assisted machining
Optical surface
Microstructure
Finite element method
MECHANICAL-PROPERTIES
MICROSTRUCTURE
EVOLUTION
BEHAVIOR
METAL
Issue Date: 1-Jun-2020
Publisher: ELSEVIER SCIENCE SA
Citation: Bai, Yuchao, Shi, Zhuoqi, Lee, Yan Jin, Wang, Hao (2020-06-01). Optical surface generation on additively manufactured AlSiMg0.75 alloys with ultrasonic vibration-assisted machining. JOURNAL OF MATERIALS PROCESSING TECHNOLOGY 280. ScholarBank@NUS Repository. https://doi.org/10.1016/j.jmatprotec.2020.116597
Abstract: © 2020 Elsevier B.V. Additive manufacturing technology provides a feasible solution to directly manufacture optical components with complex functional structure. However, the poor surface quality and low relative density result in the limitation on its rapid application. In order to overcome the above shortcomings, process optimization and ultrasonic elliptical vibration-assisted machining (UEVAM) were used in the fabrication of optical surfaces on selective laser melted (SLM) AlSiMg0.75 alloy. The optimised energy density in the SLM process was identified ranging from 65 to 130 J/mm3 with the highest achievable relative density of 99.6 %. Post-processing heat treatment changed the cellular/dendritic microstructure of as-built samples to an α-Al matrix embedded with Si particles, which reduced the microcutting forces by 27.67 % and improved the machined surface roughness (Ra) by 8.7 % during conventional microcutting. In contrast, the UEVAM process is capable of further improving the surface quality from 11.03–5.1 nm Ra, without heat treatment. It is also evident that poor machined surface quality was attributed to the formation of oxide particles during SLM. Chip morphology analysis and finite element method simulations revealed the benefits of UEVAM in tackling the issue of precipitation and extended our understanding of the applications of UEVAM.
Source Title: JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
URI: https://scholarbank.nus.edu.sg/handle/10635/168873
ISSN: 09240136
10976787
DOI: 10.1016/j.jmatprotec.2020.116597
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