Effects of Different Process Strategies on Surface Quality and Mechanical Properties of 316L Stainless Steel Fabricated via Hybrid Additive-Subtractive Manufacturing

Zihao Cai; Yongqiang Zhu; Changjun Han; Shao He; Ye He; Zhiheng Tai; Vyacheslav Trofimov; Yongqiang Yang

doi:10.3788/CJL221356

Chinese Journal of Lasers, Volume. 50, Issue 8, 0802301(2023)

Effects of Different Process Strategies on Surface Quality and Mechanical Properties of 316L Stainless Steel Fabricated via Hybrid Additive-Subtractive Manufacturing

Zihao Cai¹, Yongqiang Zhu¹, Changjun Han^1、*, Shao He², Ye He³, Zhiheng Tai¹, Vyacheslav Trofimov¹, and Yongqiang Yang¹

Author Affiliations

¹School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, Guangdong , China

²Department of Science and Technology Management, China Nuclear Power Technology Research Institute, Shenzhen 518000, Guangdong , China

³Research Institute of Reactive Waste and Radiochemistry, China Nuclear Power Technology Research Institute, Shenzhen 518000, Guangdong , China

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Figures & Tables(20)

Fig. 1. Robotic additive-subtractive hybrid manufacturing system

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Fig. 2. Morphology of single melt track formed with laser power of 2000 W, scanning speed of 12 mm/s, and powder feed speed of 24 g/min. (a) Surface morphology; (b) sectional morphology

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Fig. 3. Schematic illustration of different process strategies of additive/subtractive hybrid manufacturing. (a) Milling after additive manufacturing (AM); (b) additive manufacturing accompanying with milling; (c) tensile samples fabricated by two manufacturing strategies

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Fig. 4. Sectional images of 316L samples fabricated by LDED with different hatch space values (a)-(e) and forming diagrams(f)-(h). (a) 2 mm; (b) 2.5 mm; (c) 3 mm; (d) 3.5 mm; (e) 4 mm; (f) appropriate hatch space; (g) overlarge hatch space; (h) excessive small hatch space

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Fig. 5. Height and mechanical properties of samples formed under different hatch space values. (a) Height; (b) mechanical property

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Fig. 6. Roughness and three-dimensional morphology of 316L stainless steel milled surface. (a) Roughness R_a of milled surface under different combinations of level and factor; (b) absolute value S_a between roughness of each point and mean roughness $\bar{R}$ _a; (c) 3D surface morphology of sample in No. 3 experiment; (d) 3D surface morphology of sample in No. 7 experiment

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Fig. 7. Variation trend of S_a with different milling parameters. (a) Spindle speed; (b) feed rate; (c) milling width; (d) milling depth

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Fig. 8. Samples fabricated by milling after additive manufacturing strategy and forming process diagram. (a) Sample photo; (b) forming schematic

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Fig. 9. Flow diagram of additive manufacturing accompanying with milling and sectional image of formed sample. (a) Flow diagram; (b) sectional image

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Fig. 10. Surface roughness and microhardness comparisons of fabricated samples made by milling after additive manufacturing and additive manufacturing accompanying with milling

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Fig. 11. Tensile properties of fabricated samples by two process strategies

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Fig. 12. Fracture morphology of tensile samples. (a) Additive manufacturing accompanying with milling; (b) milling after additive manufacturing

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Fig. 13. Flow chart of additive manufacturing accompanying with milling of valve mould

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Fig. 14. Additive manufacturing accompanying with milling sequence diagram of valve mould

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Fig. 15. Additive manufacturing accompanying with milling of valve mould. (a) Photo of on-site processing; (b) mould after rough milling; (c) mould after fine milling

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Table 1. Factor level table of milling test
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Table 1. Factor level table of milling test
Level Factor
A（spindle speed）
n /（r∙min^-1）
B（feed rate）
F /（mm∙s^-1）
C（milling depth）
a_p /mm
D（milling width）
a_e /mm
1 2400 3 0.1 2
2 3000 4 0.2 3
3 3600 5 0.3 4

Table 2. Orthogonal test scheme
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Table 2. Orthogonal test scheme
Experiment number Factor
n /（r∙min^-1） F /（mm∙s^-1） a_p /mm a_e /mm
1 2400 3 0.1 2
2 2400 4 0.2 3
3 2400 5 0.3 4
4 3000 3 0.2 4
5 3000 4 0.3 2
6 3000 5 0.1 3
7 3600 3 0.3 3
8 3600 4 0.1 4
9 3600 5 0.2 2

Table 3. Average value $\bar{S}$ _a of absolute roughness value
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Table 3. Average value $\bar{S}$ _a of absolute roughness value
Experiment Number 1 2 3 4 5 6 7 8 9
$\bar{S}$ _a /μm 1.67 1.38 1.70 0.94 1.43 0.87 0.46 0.55 1.26

Table 4. Range analysis of surface roughness

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Table 4. Range analysis of surface roughness

Factor	A（spindle speed）	B（feed rate）	C（milling depth）	D（milling width）
${\bar{k}}_{1}_{j}$	1.58	1.02	1.03	1.45
${\bar{k}}_{2}_{j}$	1.08	1.12	1.19	0.90
${\bar{k}}_{3}_{j}$	0.75	1.27	1.19	1.06
$R_{j}$	0.83	0.25	0.16	0.55
Factor primary and secondary	A>D>B>C
Excellent combination	A₃B₁C₃D₂

Table 5. Additive manufacturing accompanying with milling parameters of valve mould

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Table 5. Additive manufacturing accompanying with milling parameters of valve mould

AM parameter	Laser power /W		Scan speed /（mm∙s^-1）	Powder feed rate /（g∙min^-1）	Hatch space /mm
AM parameter	2000		12	24	2.5
Milling parameter	Tool	Spindle speed /（r∙min^-1）	Feed rate /（mm∙s^-1）	Milling depth /mm	Milling width /mm
	D10	3600	5	0.3	4
	D6	3600	3	0.3	3
	R3	3600	3	0.1	0.3

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Zihao Cai, Yongqiang Zhu, Changjun Han, Shao He, Ye He, Zhiheng Tai, Vyacheslav Trofimov, Yongqiang Yang. Effects of Different Process Strategies on Surface Quality and Mechanical Properties of 316L Stainless Steel Fabricated via Hybrid Additive-Subtractive Manufacturing[J]. Chinese Journal of Lasers, 2023, 50(8): 0802301

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