Modeling of roughness and surface residual stress behavior of maraging steel manufactured by powder bed fusion and post-processed with milling

• Grant number: 21/09890-5
• Support Opportunities: Scholarships in Brazil - Doctorate
• Start date: April 01, 2022
• End date: July 31, 2026
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Erik Gustavo Del Conte
• Grantee: Amanda Rossi de Oliveira
• Host Institution: Centro de Engenharia, Modelagem e Ciências Sociais Aplicadas (CECS). Universidade Federal do ABC (UFABC). Ministério da Educação (Brasil). Santo André , SP, Brazil
• Associated scholarship(s): 23/09737-8 - Residual stress prediction on laser powder bed fusion manufacturing, BE.EP.DR

Abstract

The fabrication versatility provided with additive manufacturing stands out in the context of automation and integration supported by the 4.0 Industry. Hence, there is a need to look for alternatives to overcome the surface finishing limitations obtained with the additive technology of Powder Bed Fusion (PBF), for example, using milling with adequate cutting parameters. In this sense, it becomes important to develop strategies for predicting the surface quality of the products, considering the combined processing. That said, the research to be conducted seeks to model the roughness and surface residual stress of maraging steel manufactured by Powder Bed Fusion and post-processed with milling. For this, experiments will be performed based on the Design of Experiments with different build orientations in PBF and levels of cutting speed and feed in finishing with milling, before and after aging. Cutting power will also be monitored during milling operations. The obtained results will be submitted to statistical analyses, and the relationship between processing parameters and the maraging steel surface quality will be investigated. Thus, prediction models of roughness and surface residual stress will be elaborated using machine learning techniques, contributing to reach the desired quality for products. (AU)