Evaluation of post processing operations of parts manufactured using hybrid manufacturing (Mfh) for roughness

• Grant number: 20/00035-2
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Start date: February 01, 2020
• End date: July 31, 2021
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Reginaldo Teixeira Coelho
• Grantee: Iago José Vasques
• Host 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

Hybrid Manufacturing (MfH) combines processes of addition (MA) and material removal by machining, using this strategy can increase the manufacturing efficiency of various products. It is common for many types of parts to have complex geometries and require low roughness to function properly, so manufacturing them typically involves a sequence of manufacturing processes as well as the removal of material in the form of waste. MA does not yet have the ability to produce low roughness components, preventing their immediate application. To achieve low roughness values, machining processes should be used for the post-processing of these components. This project seeks to examine the roughness limits that can be obtained at each post-processing step of a MA fabricated part using the Directed Energy Deposition (DED) process. Parts will be fabricated by MA using this process and then milled, ground and finally polished by Magnetic Abrasive Finishing (MAF) as well as a rotary tool on the same machine tool used in the MfH process. At the end of each step, the roughness of the part will be evaluated and compared with the previous steps. Each post-processing process will be optimized aiming to minimize the roughness values, according to several evaluation parameters. Thus, it is intended through this work to verify which of these three post-processing strategies are necessary for the surface of a part obtained by MfH to reach a specific roughness, thus reducing the post-processing time and the manufacturing sequence. (AU)