PhD Research Project: Finishing of parts manufactured by additive manufacturing through machining
The ASTM F2729-12 standard defines additive manufacturing (AM) as "the process of joining materials to make objects from 3D model data, usually layer by layer, as opposed to subtractive manufacturing methodologies, such as traditional machining". AM techniques represent a set of processes based on the manufacturing of complex parts through the addition of material. Although AM has been used to process materials for more than three decades, it has not been considered an important commercial manufacturing technology until recently mostly due to the lack of manufacturing precision and methodologies to certify AM processes. This is especially valid for AM of metals (AMM), as the main potential consumers of the AMM parts – aeronautics, defence and medicine – are highly demanding for precision and reproducibility.
However, without correct processing and finishing, AMM components can fail in the early stages of evaluation. It is commonly admitted that in order to manufacture parts using AMM it is necessary to carry out a series of subsequent treatments to reduce the internal tension, increase the precision of the piece in required areas and achieve an adequate superficial integrity that guarantees the expected fatigue life. One of the well-accepted methods for post processing of AMM parts is machining, which provides both the accuracy and a good finish where necessary. The challenge of machining of AMM parts lays in the fact that the internal structure and thus the mechanical properties of AMM materials are substantially different from the materials produced by other methods e.g. casting or forging. This makes the existing know-how in machining (machinability, surface integrity…) to a large extend obsolete and necessitates generation of the new knowledge and protocols for machining of AMM parts.
This project is intended to cover this gap and to generate the knowledge relevant for future machining processing of AMM parts.
- To study different finishing techniques for pieces produced by AMM (mainly conventional chip removal) depending on the type of piece.
- To determine differences in machinability rate between AM and conventional materials.
- To propose working conditions in each case that would guarantee the level of required surface integrity.
- To understand the differences between cutting process of conventional materials and AM manufactured materials.
Organization: Mondragon Unibertsitatea. Faculty of Engineering.
Research area: High Performance Machining.
Researcher profile: First Stage Researcher (R1).
Type of contract: Research contract - Temporary.
Job status: Full time.
Location: Arrasate-Mondragon, Gipuzkoa, SPAIN
PhD supervisor: Pedro J. Arrazola, Mondragon Unibertsitatea (email@example.com)
PhD co-supervisor: Andrey Chuvulin, CIC Nanogune (firstname.lastname@example.org)
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