Experimental Study on Hybrid Additive and Subtractive Manufacturing Processes for Improving Surface Quality

Hybrid machining has considerable potential for industrial applications. The process allows the limitations of additive manufacturing to be reduced and high-precision components to be produced. This article discusses tests determining the impact of 3D printing parameters, machining parameters, and selected milling tools on achieving defined surface roughness values in parts made of PETG (polyethylene terephthalate glycol). Perpendicular-shaped samples were printed by fused deposition modelling (FDM) using variable layer heights of 0.1 mm and 0.2 mm and variable feed rates of 90, 100, 110, and 120 mm/s. Surface roughness values, topography, and Abbott–Firestone curves were determined using a Keyence VR-6000 profilometer. Straight grooves were machined in the test samples using a DMG MORI CMX 600V milling machine with a rotary burr, single-edge spiral burr cutter and spiral endmill. The microstructure was examined using a Motic inverted microscope. The surface roughness parameters of the grooves were investigated. The results confirmed that the use of hybrid machining (with a printed layer height Lh = 0.1 mm, Vfeed = 120 mm/s, and a cutter–rotary burr) allows for lower surface roughness parameters, i.e., Ra = 1.54 μm. The relationships developed between printing, cutting, and milling tool parameters can be employed to predict the roughness parameters of filaments with similar characteristics.