Drilling Strategies for Additively Manufactured and Casted SS316L Stainless Steel
Source abstract
Abstract
Enhancing the surface characteristics of additively manufactured parts is an essential concern among the research fraternity. In order to attain a high-quality surface, various traditional and non-traditional processes have been employed. The poor machined surface quality and chip-breaking mechanism are the adverse outcomes during conventional drilling (CD). Hence, in the current research attempt, the ultrasonic-assisted drilling (UAD) method has been used to mitigate these problems for additively and casted SS316L stainless steel products. Furthermore, finite element analysis has been conducted on the ultrasonic horn, strengthening the case for adopting this technique. In order to achieve amplified amplitude at the tip of the ultrasonic horn, a modified horn has been used. A comparative study has been performed regarding thrust force, surface characteristics, and types of chip generation for additively and casted SS316L stainless steel. The influence of input process parameters such as rotational speed, feed rate, and vibration intensity on the output responses has been analyzed. Minimum thrust force accompanied with small broken chips, which have been produced during UAD process, caused the surface quality to be improved in comparison with the conventional method. During UAD process, the thrust force has been found to be significantly reduced by 31.69 % and 34.45 % for casted and additively manufactured, respectively, as compared to CD process. Additionally, UAD strategies offered a maximum reduction in surface roughness by 29.56 % as compared to CD process. The impulsive separation between drill bit and hole surface in UAD facilitated the better machinability of additively manufactured parts. This outcome can be a contributing step toward the realization of sustainable drilling processes.
Source: expertdata · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced machining processes and optimization · Advanced Machining and Optimization Techniques · Additive Manufacturing Materials and Processes
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (59)
Show source-provided references
1. Designation: F2792−12a n.d. https://doi.org/10.1520/F2792-12A10.1520/F2792-12A ↗
2. M. Kumar and V. Sharma, Additive Manufacturing Techniques for the Fabrication of Tissue Engineering Scaffolds: A Review, Rapid Prototyp. J., 2021, 27, p 1230–1272. https://doi.org/10.1108/RPJ-01-2021-001110.1108/RPJ-01-2021-0011 ↗
3. S.J. Trenfield, A. Awad, C.M. Madla, G.B. Hatton, J. Firth, A. Goyanes et al., Shaping the Future: Recent Advances of 3D Printing in Drug Delivery and Healthcare, Expert Opin. Drug Deliv., 2019, 16, p 1081–1094. https://doi.org/10.1080/17425247.2019.166031810.1080/17425247.2019.1660318 ↗
4. R.D.P. Reddy, A.K. Sahu, and S.S. Mahapatra, Investigation on Performance of a Copper Coated Hollow Rapid Electrode During Electrical Discharge Machining, Sādhanā, 2022, 47, p 173. https://doi.org/10.1007/s12046-022-01947-710.1007/s12046-022-01947-7 ↗
5. R. Durga Prasad Reddy and V. Sharma, Investigations of Hybrid Infill Pattern in Additive Manufactured Tablets: A Novel Approach Towards Tunable Drug Release, J. Biomed. Mater. Res. B Appl. Biomater., 2023, 111, p 1869–1882. https://doi.org/10.1002/jbm.b.3529010.1002/jbm.b.35290 ↗
6. S. Bremen, W. Meiners, and A. Diatlov, Selective Laser Melting, Laser Tech. J., 2012, 9, p 33–38. https://doi.org/10.1002/latj.20129001810.1002/latj.201290018 ↗
7. G. Miranda, S. Faria, F. Bartolomeu, E. Pinto, S. Madeira, A. Mateus et al., Predictive Models for Physical and Mechanical Properties of 316L Stainless Steel Produced by Selective Laser Melting, Mater. Sci. Eng. A, 2016, 657, p 43–56. https://doi.org/10.1016/j.msea.2016.01.02810.1016/j.msea.2016.01.028 ↗
8. Z. Sun, X. Tan, S.B. Tor, and W.Y. Yeong, Selective Laser Melting of Stainless Steel 316L with Low Porosity and High Build Rates, Mater. Des., 2016, 104, p 197–204. https://doi.org/10.1016/j.matdes.2016.05.03510.1016/j.matdes.2016.05.035 ↗
9. H. Gong, D. Snelling, K. Kardel, and A. Carrano, Comparison of Stainless Steel 316L Parts Made by FDM- and SLM-Based Additive Manufacturing Processes, JOM, 2019, 71, p 880–885. https://doi.org/10.1007/s11837-018-3207-310.1007/s11837-018-3207-3 ↗
10. L. Gardner, Stability and Design of Stainless Steel Structures—Review and Outlook, Thin-Walled Struct., 2019, 141, p 208–216. https://doi.org/10.1016/J.TWS.2019.04.01910.1016/J.TWS.2019.04.019 ↗
11. E. Yarar and S. Karabay, Investigation of the Effects of Ultrasonic Assisted Drilling on Tool Wear and Optimization of Drilling Parameters, CIRP J. Manuf. Sci. Technol., 2020, 31, p 265–280. https://doi.org/10.1016/j.cirpj.2020.06.00210.1016/j.cirpj.2020.06.002 ↗
12. Z. Sun, D. Geng, F. Meng, L. Zhou, X. Jiang, and D. Zhang, High performance Drilling of T800 CFRP Composites by Combining Ultrasonic Vibration and Optimized Drill Structure, Ultrasonics, 2023 https://doi.org/10.1016/j.ultras.2023.10709710.1016/j.ultras.2023.107097 ↗
13. A.K. Singh and V. Sharma, A comparative Appraisal of Sustainable Strategy in Ultrasonic Assisted Grinding of Nimonic 80A using Novel Green Atomized Cutting Fluid, Sustain. Mater. Technol., 2022 https://doi.org/10.1016/j.susmat.2022.e0042310.1016/j.susmat.2022.e00423 ↗
14. A.K. Singh, V. Sharma, and P.M. Pandey, Predictive Model for Cutting Forces and Specific Cutting Energy in Ultrasonic-Assisted Grinding Process: A Mechanistic Approach, Int. J. Adv. Manuf. Technol., 2022, 122, p 2953–2969. https://doi.org/10.1007/s00170-022-10068-810.1007/s00170-022-10068-8 ↗
15. D. Geng, Y. Liu, Z. Shao, Z. Lu, J. Cai, X. Li et al., Delamination Formation, Evaluation and Suppression during Drilling of Composite Laminates: A Review, Compos. Struct., 2019, 216, p 168–186. https://doi.org/10.1016/j.compstruct.2019.02.09910.1016/j.compstruct.2019.02.099 ↗
16. R. Neugebauer and A. Stoll, Ultrasonic Application in Drilling, J. Mater. Process. Technol., 2004, 149, p 633–639. https://doi.org/10.1016/j.jmatprotec.2003.10.06210.1016/j.jmatprotec.2003.10.062 ↗
17. X.X. Zhu, W.H. Wang, R.S. Jiang, Z.F. Zhang, B. Huang, and X.W. Ma, Research on Ultrasonic-Assisted Drilling in Micro-Hole Machining of the DD6 Superalloy, Adv. Manuf., 2020, 8, p 405–417. https://doi.org/10.1007/s40436-020-00301-610.1007/s40436-020-00301-6 ↗
18. Y. Tian, P. Zou, D. Kang, and F. Fan, Study on Tool Wear in Longitudinal-Torsional Composite Ultrasonic Vibration-Assisted Drilling of Ti-6Al-4V Alloy, Int. J. Adv. Manuf. Technol., 2021, 113, p 1989–2002. https://doi.org/10.1007/s00170-021-06759-310.1007/s00170-021-06759-3 ↗
19. L. Wei and D. Wang, Comparative Study on Drilling Effect Between Conventional Drilling and Ultrasonic-Assisted Drilling of Ti-6Al-4V/Al2024-T351 Laminated Material, Int. J. Adv. Manuf. Technol., 2019, 103, p 141–152. https://doi.org/10.1007/s00170-019-03507-610.1007/s00170-019-03507-6 ↗
20. A.N. Dahnel, H. Ascroft, and S. Barnes, The Effect of Varying Cutting Speeds on Tool Wear during Conventional and Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC) and Titanium Alloy Stacks, Procedia CIRP, 2016, 46, p 420–423. https://doi.org/10.1016/j.procir.2016.04.04410.1016/j.procir.2016.04.044 ↗
21. F. Makhdum, V.A. Phadnis, A. Roy, and V.V. Silberschmidt, Effect of Ultrasonically-Assisted Drilling on Carbon-Fibre-Reinforced Plastics, J. Sound Vib., 2014, 333, p 5939–5952. https://doi.org/10.1016/j.jsv.2014.05.04210.1016/j.jsv.2014.05.042 ↗
22. F. Makhdum, D.N.P. Norddin, A. Roy, and V.V. Silberschmidt, Ultrasonically Assisted Drilling of Carbon Fibre Reinforced Plastics, Solid State Phenom., 2012, 188, p 170–175. https://doi.org/10.4028/www.scientific.net/SSP.188.17010.4028/www.scientific.net/SSP.188.170 ↗
23. H. Paktinat and S. Amini, Experiments and Finite Element Simulation of Ultrasonic Assisted Drilling, J. Manuf. Sci. Eng. Trans. ASME, 2018 https://doi.org/10.1115/1.404032110.1115/1.4040321 ↗
24. B.V. Azghandi, M.A. Kadivar, and M.R. Razfar, An Experimental Study on Cutting Forces in Ultrasonic Assisted Drilling, Procedia CIRP, 2016, 46, p 563–566. https://doi.org/10.1016/j.procir.2016.04.07010.1016/j.procir.2016.04.070 ↗
25. V.A. Bijan and R.M. Reza, An Experimental Study on the Effects of Ultrasonic Assisted Drilling on Chip Characteristics and Tool Life, Adv. Mater. Res., 2011, 325, p 351–356. https://doi.org/10.4028/www.scientific.net/AMR.325.35110.4028/www.scientific.net/AMR.325.351 ↗
26. V. Baghlani, P. Mehbudi, J. Akbari, E.Z. Nezhad, A.A.D. Sarhan, and A.M.S. Hamouda, An Optimization Technique on Ultrasonic and Cutting Parameters for Drilling and Deep Drilling of Nickel-Based High-Strength Inconel 738LC Superalloy with Deeper and Higher Hole Quality, Int. J. Adv. Manuf. Technol., 2016, 82, p 877–888. https://doi.org/10.1007/s00170-015-7414-610.1007/s00170-015-7414-6 ↗
27. Y. Tian, P. Zou, X. Yang, and D. Kang, Study on Chip Morphology and Surface Roughness in Ultrasonically Assisted Drilling of 304 Stainless Steel, Int. J. Adv. Manuf. Technol., 2020, 108, p 2079–2090. https://doi.org/10.1007/s00170-020-05440-5/Published10.1007/s00170-020-05440-5/Published ↗
28. Gürgen S, Sofuoğlu MA. Chapter 4 - Advancements in conventional machining: a case of vibration and heat-assisted machining of aerospace alloys. In: Gupta K, Pramanik A, editors. Advanced Machining and Finishing, Elsevier; 2021, p. 143–75. https://doi.org/10.1016/B978-0-12-817452-4.00015-4.10.1016/B978-0-12-817452-4.00015-4 ↗
29. A.J. Shih, J. Luo, M.A. Lewis, and J.S. Strenkowski, Chip Morphology and Forces in End Milling of Elastomers, J. Manuf. Sci. Eng., 2004, 126, p 124–130. https://doi.org/10.1115/1.163327610.1115/1.1633276 ↗
30. M.S. Kumar, A. Prabukarthi, and V. Krishnaraj, Study on Tool Wear and Chip Formation during Drilling Carbon Fiber Reinforced Polymer (CFRP)/Titanium Alloy (Ti6Al4V) Stacks, Procedia Eng., 2013, 64, p 582–592. https://doi.org/10.1016/j.proeng.2013.09.13310.1016/j.proeng.2013.09.133 ↗
31. G. Chen, J. Xu, J. Wang, Y. Li, J. Wang, and H. Yu, Experimental Investigation on Cavitation Effect and Surface Quality of Ultrasonic-Assisted Micro-Hole Drilling, Int. J. Adv. Manuf. Technol., 2022, 121, p 919–936. https://doi.org/10.1007/s00170-022-09193-110.1007/s00170-022-09193-1 ↗
32. Y. Liu, D. Geng, D. Zhang, Y. Zhai, L. Liu, Z. Sun et al., Cutting performance and Surface Integrity for Rotary Ultrasonic Elliptical Milling of Inconel 718 with the Ball End Milling Cutter, J. Mater. Process. Technol., 2023 https://doi.org/10.1016/j.jmatprotec.2023.11809410.1016/j.jmatprotec.2023.118094 ↗
33. L. Kumar Patel, A. Kumar Singh, V. Sharma, and P. Kala, Analysis of a Hybrid Ultrasonic Horn Profile using Finite Element Analysis, Mater. Today Proc., 2020, 41, p 772–779. https://doi.org/10.1016/j.matpr.2020.08.46510.1016/j.matpr.2020.08.465 ↗
34. Mukhtar M. Performance of Tialn Coated Carbide Tool in Peck Drilling Stainless Steel SS316L with Pressurized Minimum Quantity Lubrication (PMQL). 2014.
35. C. Liu, M. Wan, W. Zhang, and Y. Yang, Chip Formation Mechanism of Inconel 718: A Review of Models and Approaches, Chin. J. Mech. Eng. (Engl. Ed.), 2021, 3, p 4. https://doi.org/10.1186/s10033-021-00552-910.1186/s10033-021-00552-9 ↗
36. Z. Deyuan and W. Lijiang, Investigation of Chip in Vibration Drilling, Int. J. Mach. Tools Manuf, 1998, 38(3), p 165–176.10.1016/S0890-6955(97)00047-3 ↗
37. A. Röttger, J. Boes, W. Theisen, M. Thiele, C. Esen, A. Edelmann et al., Microstructure and Mechanical Properties of 316L Austenitic Stainless Steel Processed by Different SLM Devices, Int. J. Adv. Manuf. Technol., 2020, 108, p 769–783. https://doi.org/10.1007/s00170-020-05371-110.1007/s00170-020-05371-1 ↗
38. C.F. de Oliveira, A.C. Araujo, A.L. Jardini Munhoz, and S.G. Kapoor, The Influence of Additive Manufacturing on the Micromilling Machinability of Ti6Al4V: A Comparison of SLM and Commercial Workpieces, J. Manuf. Process., 2020, 60, p 299–307. https://doi.org/10.1016/j.jmapro.2020.10.00610.1016/j.jmapro.2020.10.006 ↗
39. A. Abdelkawy, M. Hossam, and H. El-Hofy, Experimental Investigation of the Cutting Forces and Edge Chipping in Ultrasonic-Assisted Drilling of Soda Glass, Int. J. Adv. Manuf. Technol., 2019, 100, p 1433–1449. https://doi.org/10.1007/s00170-018-2771-610.1007/s00170-018-2771-6 ↗
40. Q.-H. Ngo and K.-T. Ho, An Experimental Study on Ultrasonic Assisted Drilling of Stainless Steel AISI SUS 304, Int. J. Adv. Eng. Manag. (IJAEM), 2021, 3, p 256. https://doi.org/10.35629/5252-030625626110.35629/5252-0306256261 ↗
41. S. Hameed, H.A.G. Rojas, J.I.P. Benavides, A.N. Alberro, and A.J.S. Egea, Influence of the Regime of Electropulsing-Assisted Machining on the Plastic Deformation of the Layer Being Cut, Materials, 2018 https://doi.org/10.3390/ma1106088610.3390/ma11060886 ↗
42. D. Geng, Z. Lu, G. Yao, J. Liu, Z. Li, and D. Zhang, Cutting Temperature and Resulting Influence on Machining Performance in Rotary Ultrasonic Elliptical Machining of Thick CFRP, Int. J. Mach. Tools Manuf, 2017, 123, p 160–170. https://doi.org/10.1016/j.ijmachtools.2017.08.00810.1016/j.ijmachtools.2017.08.008 ↗
43. Y. Chen, Y. Liang, J. Xu, and A. Hu, Ultrasonic Vibration Assisted Grinding of CFRP Composites: Effect of Fiber Orientation and Vibration Velocity on Grinding Forces and Surface Quality, Int. J. Lightweight Mater. Manuf., 2018, 1, p 189–196. https://doi.org/10.1016/j.ijlmm.2018.08.00310.1016/j.ijlmm.2018.08.003 ↗
44. S. Orak, R.A. Arapoğlu, and M.A. Sofuoğlu, Development of an ANN-Based Decision-Making Method for Determining Optimum Parameters in Turning Operation, Soft. Comput., 2018, 22, p 6157–6170. https://doi.org/10.1007/s00500-017-2682-810.1007/s00500-017-2682-8 ↗
45. A.I. Azmi, R.J.T. Lin, and D. Bhattacharyya, Machinability Study of Glass Fibre-Reinforced Polymer Composites during end Milling, Int. J. Adv. Manuf. Technol., 2013, 64, p 247–261. https://doi.org/10.1007/s00170-012-4006-610.1007/s00170-012-4006-6 ↗
46. R. Teimouri, S. Amini, M. Lotfi, and M. Alinaghian, Sustainable Drilling Process of 1045 Steel Plates Regarding Minimum Energy Consumption and Desired Work Quality, Int. J. Lightweight Mater. Manuf., 2019, 2, p 397–406. https://doi.org/10.1016/j.ijlmm.2019.04.01110.1016/j.ijlmm.2019.04.011 ↗
47. M.A. Sofuoğlu, F.H. Çakır, M.C. Kuşhan, and S. Orak, Optimization of Different Non-traditional Turning Processes using Soft Computing Methods, Soft. Comput., 2019, 23, p 5213–5231. https://doi.org/10.1007/s00500-018-3471-810.1007/s00500-018-3471-8 ↗
48. R. Molaei, A. Fatemi, and N. Phan, Multiaxial Fatigue of LB-PBF Additive Manufactured 17–4 PH Stainless Steel Including the Effects of Surface Roughness and HIP Treatment and Comparisons with the Wrought Alloy, Int. J. Fatigue, 2020 https://doi.org/10.1016/j.ijfatigue.2020.10564610.1016/j.ijfatigue.2020.105646 ↗
49. U. Köklü, O. Koçar, S. Morkavuk, K. Giasin, and Ö. Ayer, Influence of Extrusion Parameters on Drilling Machinability of AZ31 Magnesium Alloy, Proc. Inst. Mech. Eng. Part E J. Process. Mech. Eng., 2022, 236, p 2082–2094. https://doi.org/10.1177/0954408922108082010.1177/09544089221080820 ↗
50. A. Çiçek et al., Performance of Cryogenically Treated M35 HSS Drills in Drilling Of Austenitic Stainless Steels, Int. J. Adv. Manuf. Technol., 2012, 60, p 65–73. https://doi.org/10.1007/s00170-011-3616-810.1007/s00170-011-3616-8 ↗
51. M. Bakkal, A.J. Shih, S.B. McSpadden, C.T. Liu, and R.O. Scattergood, Light Emission, Chip Morphology, and Burr Formation in Drilling the Bulk Metallic Glass, Int. J. Mach. Tools Manuf, 2005, 45, p 741–752. https://doi.org/10.1016/j.ijmachtools.2004.11.00410.1016/j.ijmachtools.2004.11.004 ↗
52. T. Kanagaraju, L.G. Babu, V.M. Madhavan, V. Sivaraman, B. Gowthaman, K. Arul et al., Experimental Analysis on Drilling of Super Duplex Stainless Steel 2507 (SDSS 2507) using Cryogenic LCO2 and MQL Process, Biomass. Convers. Biorefin., 2022 https://doi.org/10.1007/s13399-022-02536-810.1007/s13399-022-02536-8 ↗
53. Ş Yazman, L. Gemı, M. Uludağ, A. Akdemır, M. Uyaner, and D. Dişpinar, Correlation Between Machinability and Chip Morphology of Austempered Ductile Iron, J. Test. Eval., 2018, 46, p 20160490. https://doi.org/10.1520/JTE2016049010.1520/JTE20160490 ↗
54. Z. Zhu, K. Guo, J. Sun, J. Li, Y. Liu, L. Chen et al., Evolution of 3D Chip Morphology and Phase Transformation in Dry Drilling Ti6Al4V Alloys, J. Manuf. Process., 2018, 34, p 531–539. https://doi.org/10.1016/j.jmapro.2018.07.00110.1016/j.jmapro.2018.07.001 ↗
55. L. Pelikán, M. Slaný, O. Stránský, L. Beránek, Z. Pitrmuc, L. Čepová et al., Novel Drill Geometries for Dry Drilling of Stainless Steel, J. Manuf. Process., 2023, 92, p 500–520. https://doi.org/10.1016/j.jmapro.2023.03.00610.1016/j.jmapro.2023.03.006 ↗
56. P.F. Zhang, N.J. Churi, Z.J. Pei and C. Treadwell, Mechanical Drilling Processes for Titanium Alloys: A Literature Review, Mach. Sci. Technol., 2008, 12, p 417–444. https://doi.org/10.1080/1091034080251937910.1080/10910340802519379 ↗
57. S.A. Batzer, D.M. Haan, P.D. Rao, W.W. Olson and J.W. Sutherland, Chip Morphology and Hole Surface Texture in the Drilling of Cast Aluminum Alloys, J. Mater. Process. Technol., 1998, 79(1–3), p 72–78.10.1016/S0924-0136(97)00324-5 ↗
58. K. Liu, J. Li, J. Sun, Z. Zhu and H. Meng, Investigation on Chip Morphology and Properties in Drilling Aluminum and Titanium Stack with Double Cone Drill, Int. J. Adv. Manuf. Technol., 2018, 94, p 1947–1956. https://doi.org/10.1007/s00170-017-0988-410.1007/s00170-017-0988-4 ↗
59. F. Bartolomeu, M. Buciumeanu, E. Pinto, N. Alves, O. Carvalho, F.S. Silva et al., 316L Stainless Steel Mechanical and Tribological Behavior—A Comparison Between Selective Laser Melting, Hot Pressing and Conventional Casting, Addit. Manuf., 2017, 16, p 81–89. https://doi.org/10.1016/j.addma.2017.05.00710.1016/j.addma.2017.05.007 ↗