University of Twente Student Theses
Assessment of milling stability of LPBF-manufactured 316L flexible elements
Janssen, M.M. (2024) Assessment of milling stability of LPBF-manufactured 316L flexible elements.
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| Full Text Status: | Access to this publication is restricted |
| Embargo date: | 29 June 2029 |
| Abstract: | The outset of this thesis is a complex high-tech component, of which the current manufacturing process primarily consists of machining the geometry from 316L stainless steel stock in a 35-hour milling operation. It is anticipated that the Laser Powder Bed Fusion (LPBF) process could eliminate a substantial portion of the machining operations. However, to meet strict accuracy demands, finishing machining would still be required for certain component features, including flexible elements. These elements, intentionally designed with limited rigidity, deflect even under minimal cutting forces exerted by the milling cutter, resulting in chatter. Limiting the chatter of the flexible elements to an acceptable level is necessary to eventually render the high-tech component suitable for LPBF fabrication. In this thesis, a Finite Element Method (FEM) model is established to predict the milling stability of LPBF-manufactured flexible elements. The model incorporates two simplified sample geometries with varying rigidities. Kienzle’s empirical force model is utilized to determine cutting force components under varying cutting conditions, which are then integrated into the FEM model. Finally, the FEM model evaluates the development of vibration when the tooth passing frequency, which excites the system during milling, approaches the natural frequency of the system. The FEM predictions are verified through milling experiments, wherein the vibrations are measured with an accelerometer sensor and captured using a high-speed camera. |
| Item Type: | Essay (Master) |
| Clients: | KMWE, Eindhoven, The Netherlands |
| Faculty: | ET: Engineering Technology |
| Subject: | 52 mechanical engineering |
| Programme: | Mechanical Engineering MSc (60439) |
| Link to this item: | https://purl.utwente.nl/essays/100313 |
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