<p>Additively manufactured titanium alloy parts present challenges, including internal defects and rough surfaces. Consequently, the study of their surface machining laws is significant for the purpose of surface post-processing, intending to enhance surface integrity. As a flexible finishing process, abrasive belt grinding has the potential to enhance the quality of the machined surface significantly. In the case of the Ti6Al4V manufactured by selective laser melting (SLM), belt grinding experiments were carried out in this study regarding the grinding law and surface integrity investigation. The machined surface exhibited superior surface quality at elevated grinding speeds and reduced feed rates, with a notable reduction in surface roughness from 5.83&#xa0;μm to a minimum value of 1.13&#xa0;μm. On this basis, the surface integrity was discussed from the perspective of surface profile, subsurface morphology, residual stress, and microhardness. The formation mechanism of surface grinding morphology was also analyzed and summarized. The findings indicated that at low grinding speeds and high feed rates, the tearing surface at the edges of grinding marks was susceptible to forming fin-shaped extruded material, which was prone to detachment following disturbance and increases surface roughness. Furthermore, the tissue damage caused by the presence of pores and the application of considerable grinding forces could lead to the formation of micro-cracks in the subsurface, particularly within the coarse α laths that were densely distributed around the pores. The findings of this study can inform the development of guidelines for the high-quality processing of additive manufacturing titanium alloys.</p> Graphical Abstract <p></p>

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Morphology formation mechanism and surface integrity of grinding additive manufactured Ti6Al4V with abrasive belt

  • Tangming Zhang,
  • Lai Zou,
  • Xiaoyu Zhao,
  • Wenxi Wang,
  • Youdong Zhang

摘要

Additively manufactured titanium alloy parts present challenges, including internal defects and rough surfaces. Consequently, the study of their surface machining laws is significant for the purpose of surface post-processing, intending to enhance surface integrity. As a flexible finishing process, abrasive belt grinding has the potential to enhance the quality of the machined surface significantly. In the case of the Ti6Al4V manufactured by selective laser melting (SLM), belt grinding experiments were carried out in this study regarding the grinding law and surface integrity investigation. The machined surface exhibited superior surface quality at elevated grinding speeds and reduced feed rates, with a notable reduction in surface roughness from 5.83 μm to a minimum value of 1.13 μm. On this basis, the surface integrity was discussed from the perspective of surface profile, subsurface morphology, residual stress, and microhardness. The formation mechanism of surface grinding morphology was also analyzed and summarized. The findings indicated that at low grinding speeds and high feed rates, the tearing surface at the edges of grinding marks was susceptible to forming fin-shaped extruded material, which was prone to detachment following disturbance and increases surface roughness. Furthermore, the tissue damage caused by the presence of pores and the application of considerable grinding forces could lead to the formation of micro-cracks in the subsurface, particularly within the coarse α laths that were densely distributed around the pores. The findings of this study can inform the development of guidelines for the high-quality processing of additive manufacturing titanium alloys.

Graphical Abstract