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Design optimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting
Graphical abstract Display Omitted
Highlights Overhanging structures manufactured for selective laser melting were analysed. The samples were fabricated in AlSi10Mg and Ti6Al4V alloys. Taguchi method was used for the optimization of the support structures. The fabrication of non-assembly mechanisms by SLM was demonstrated.
Abstract Selective laser melting (SLM) process allows fabricating strong, lightweight and complex metallic structures. To successfully produce metallic parts by SLM, additional structures are needed to support overhanging surfaces in order to dissipate process heat and to minimize geometrical distortions induced by internal stresses. However, these structures are often massive and require additional post-processing for their removal. A minimization of support structures would therefore significantly reduce manufacturing and finishing efforts and costs. This study investigates the manufacturability of overhanging structures using optimized support parts. An experimental study was performed to identify the optimal self-supporting overhanging structures using Taguchi L 36 design. Experimental results revealed that with optimized supports it is possible to build non-assembly mechanism with overhang surfaces. However, it is necessary to correctly orientate the part in the SLM machine in order to build it with a minimal support structure so to obtain the best trade-off between production time, cost, and accuracy.
Design optimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting
Graphical abstract Display Omitted
Highlights Overhanging structures manufactured for selective laser melting were analysed. The samples were fabricated in AlSi10Mg and Ti6Al4V alloys. Taguchi method was used for the optimization of the support structures. The fabrication of non-assembly mechanisms by SLM was demonstrated.
Abstract Selective laser melting (SLM) process allows fabricating strong, lightweight and complex metallic structures. To successfully produce metallic parts by SLM, additional structures are needed to support overhanging surfaces in order to dissipate process heat and to minimize geometrical distortions induced by internal stresses. However, these structures are often massive and require additional post-processing for their removal. A minimization of support structures would therefore significantly reduce manufacturing and finishing efforts and costs. This study investigates the manufacturability of overhanging structures using optimized support parts. An experimental study was performed to identify the optimal self-supporting overhanging structures using Taguchi L 36 design. Experimental results revealed that with optimized supports it is possible to build non-assembly mechanism with overhang surfaces. However, it is necessary to correctly orientate the part in the SLM machine in order to build it with a minimal support structure so to obtain the best trade-off between production time, cost, and accuracy.
Design optimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting
Calignano, F. (author)
2014-07-22
11 pages
Article (Journal)
Electronic Resource
English
| British Library Online Contents | 2014
Selective laser melting of aluminum alloys
| British Library Online Contents | 2017