Design model for the knowledge-based adjustment of the edge zone and surface properties of additive-manufactured components for guided centrifugal finishing

• Applicant: Professor Dr.-Ing. Thomas Bergs
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2020 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 429960079

The challenge facing civil aviation is to cope with increasing passenger volumes while simultaneously reducing pollutant emissions. Therefore, there is a high demand for innovative manufacturing technologies that make it possible to increase engine efficiency. Additive manufacturing makes it possible to achieve weight savings by optimizing the topology of components with complex geometries such as turbine blades. The additive production of turbine blades can thus save fuel and increase engine efficiency. Due to the high surface roughness and thermally influenced edge zone properties resulting from additive manufacturing, post-processing of the edge zone is often necessary. Guided centrifugal finishing offers the potential to evenly machine the surface of components with a complex geometry. The cause-effect relationships between the process input variables and the resulting edge zone and surface properties in guided centrifugal finishing have not yet been systematically investigated. A knowledge-based process design is therefore not yet possible.The goal of the research project is therefore a heuristic explanatory model which explains the influence of the edge zone and surface properties of additively manufactured components during guided centrifugal finishing as a function of the local contact conditions. The cause-effect relationships between the process input variables and the local contact conditions are identified. On the basis of the findings, a numerical model will be developed which represents the contact between the abrasive media and the workpiece. The numerical model enables the prediction of the resulting edge zone properties as a function of the local contact conditions. Subsequently, the cause-effect relationships between the local contact conditions and the edge zone and surface properties of additively manufactured components made of Inconel 718 are identified after guided centrifugal finishing. The results are combined in an explanatory model which explains the cause-effect relationships between the process input variables and the edge zone and surface properties for the guided centrifugal finishing.

• DFG Programme: Research Grants