Investigations on the Effect of Layers’ Thickness and Orientations in the Machining of Additively Manufactured Stainless Steel 316L

Abstract

Laser-powder bed fusion (L-PBF) process is a family of modern technologies, in which functional, complex (3D) parts are formed by selectively melting the metallic powders layer-by-layer based on fusion. The machining of L-PBF parts for improving their quality is a difficult task. This is because different component orientations (L-PBF-layer orientations) produce different quality of machined surface even though the same cutting parameters are applied. In this paper, stainless steel grade SS 316L parts from L-PBF were subjected to the finishing (milling) process to study the effect of part orientations. Furthermore, an attempt is made to suppress the part orientation effect by changing the layer thickness (LT) of the parts during the L-PBF process. L-PBF parts were fabricated with four different layer thicknesses of 30, 60, 80 and 100 μm to see the effect of the LT on the finish milling process. The results showed that the layer thickness of 60 μm has significantly suppressed the part orientation effect as compared to the other three-layer thicknesses of 30, 80 and 100 μm. The milling results showed that the three-layer thickness including 30, 80 and 100 μm presented up to a 34% difference in surface roughness among different part orientations while using the same milling parameters. In contrast, the layer thickness of 60 μm showed uniform surface roughness for the three-part orientations having a variation of 5–17%. Similarly, the three-layer thicknesses 30, 80 and 100 μm showed up to a 25%, 34% and 56% difference of axial force (Fa), feed force (Ff) and radial force (Fr), respectively. On the other hand, the part produced with layer thickness 60 μm showed up to 11%, 25% and 28% difference in cutting force components Fa, Ff and Fr, respectively. The three-layer thicknesses 30, 80 and 100 μm in micro-hardness were found to vary by up to 14.7% for the three-part orientation. Negligible micro-hardness differences of 1.7% were revealed by the parts with LT 60 μm across different part orientations as compared to 6.5–14% variations for the parts with layer thickness of 30, 80 and 100 μm. Moreover, the parts with LT 60 μm showed uniform and superior surface morphology and reduced edge chipping across all the part orientations. This study revealed that the effect of part orientation during milling becomes minimum and improved machined surface integrity is achieved if the L-PBF parts are fabricated with a layer thickness of 60 μm.