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Study and development of post-processing in metal parts produced by additive manufacturing: application of High Speed Machining/Grinding and magnetic abrasive finishing process

Grant number: 19/10758-4
Support type:Scholarships in Brazil - Doctorate
Effective date (Start): August 01, 2019
Effective date (End): February 28, 2023
Field of knowledge:Engineering - Mechanical Engineering
Principal Investigator:Eraldo Jannone da Silva
Grantee:Adriel Magalhães Souza
Home Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
Associated research grant:16/11309-0 - The study, development and application of a hybrid process: Additive Manufacturing (AM) plus High Speed Machining/Grinding (HSM/G), AP.TEM

Abstract

Additive Manufacturing (AM), also known as 3D Printing, has been considered a high-potential disruptive technology, with significant increase in the recent years. The products made through this process are created by the addition of layers until the forming of the component becomes close to the final geometry (net shape). It can be applied to polymers, wood, ceramic, composite materials and metals. Regarding metal AM techniques, one of the main methods is Directed Energy Deposition (DED), which combines the material and energy supply for layer by layer simultaneous composition, and, consequently, the forming of the piece. However, the components made through this method present low dimensional tolerance and poor surface finish (when compared to the traditional processes of manufacturing), creating a need for post-processing. As a solution, there came up the concept of "hybrid manufacturing" or "hybrid processes", in which there is the addition and the subtraction of the material. Based upon this context, this project has as its main aim the development and post-processing in metal parts produced by AM-DED. Through High Speed Machining/Grinding (HSM/G) and the Magnetic Abrasive Finishing (MAF) process, the focus is on finding the best sequence of manufacturing through HSM+G+MAF; as well as the evaluation of strategies/conditions of the machining and the impact generated by these to the part and the development of a model of the process MAF, aiming to predict the surface roughness of the piece due to the parameters of the process. As one of the main expected conclusions, attention must be brought to the evidence regarding the potential for using technology of hybrid processes in Brazil.