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<p>This study explores the machinability performed after the fabrication of AL5356 via cold metal transfer wire arc additive manufacturing (CMT-WAAM) to enhance surface quality, achieve dimensional accuracy, and improve mechanical properties, which are essential for meeting the stringent requirements of aerospace and automotive applications. Microstructural studies revealed variations in grain size and hardness across the deposited wall, with finer grains and higher hardness in the top sections. This research focuses on optimizing end milling parameters to improve surface quality, enhance material removal rate (MRR), and minimize tool wear. A Box–Behnken experimental design was employed, incorporating key input variables: cutting speed (125.66-175.93&#xa0;m/min), axial feed rate (100-200&#xa0;mm/min), and depth of cut (0.25-0.75&#xa0;mm). The optimal machining parameters were identified as a cutting speed of 175.93&#xa0;m/min, an axial feed rate of 123.69&#xa0;mm/min, and a depth of cut of 0.25&#xa0;mm. Under these conditions, the study achieved a minimum surface roughness of 0.42&#xa0;µm, a maximum MRR of 1506.3 mm<sup>3</sup>/min, and minimized tool wear at 0.116&#xa0;mm. Microstructural characterization using electron backscatter diffraction and x-ray diffraction revealed significant variations in grain size, hardness, and phase distribution across different sections of the AL5356 wall. The top section exhibited finer grains and higher hardness values (78-87 HV) compared to the bottom section (57-69 HV), a difference attributed to reduced thermal cycling effects during deposition. Wear studies indicated self-healing behavior, driven by oxide formations (MgO and MgAl<sub>2</sub>O<sub>4</sub>), which improved frictional performance and wear resistance, particularly in the top regions. The results underline the critical balance required between machining parameters to achieve optimal surface quality, machining efficiency, and tool life. This study not only advances the understanding of machining AL5356 components fabricated through CMT-WAAM but also provides a framework for optimizing machining practices, enabling their effectiveness in industries demanding precision and durability.</p>

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Experimental Investigation and Optimization of the Machining Properties of Aluminum AL5356 Deposited with Cold Metal Transfer Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年8月25日

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  • Sachin Kumar,
  • Vishal S. Sharma,
  • Gurraj Singh,
  • Shiva Sekar

摘要

This study explores the machinability performed after the fabrication of AL5356 via cold metal transfer wire arc additive manufacturing (CMT-WAAM) to enhance surface quality, achieve dimensional accuracy, and improve mechanical properties, which are essential for meeting the stringent requirements of aerospace and automotive applications. Microstructural studies revealed variations in grain size and hardness across the deposited wall, with finer grains and higher hardness in the top sections. This research focuses on optimizing end milling parameters to improve surface quality, enhance material removal rate (MRR), and minimize tool wear. A Box–Behnken experimental design was employed, incorporating key input variables: cutting speed (125.66-175.93 m/min), axial feed rate (100-200 mm/min), and depth of cut (0.25-0.75 mm). The optimal machining parameters were identified as a cutting speed of 175.93 m/min, an axial feed rate of 123.69 mm/min, and a depth of cut of 0.25 mm. Under these conditions, the study achieved a minimum surface roughness of 0.42 µm, a maximum MRR of 1506.3 mm3/min, and minimized tool wear at 0.116 mm. Microstructural characterization using electron backscatter diffraction and x-ray diffraction revealed significant variations in grain size, hardness, and phase distribution across different sections of the AL5356 wall. The top section exhibited finer grains and higher hardness values (78-87 HV) compared to the bottom section (57-69 HV), a difference attributed to reduced thermal cycling effects during deposition. Wear studies indicated self-healing behavior, driven by oxide formations (MgO and MgAl2O4), which improved frictional performance and wear resistance, particularly in the top regions. The results underline the critical balance required between machining parameters to achieve optimal surface quality, machining efficiency, and tool life. This study not only advances the understanding of machining AL5356 components fabricated through CMT-WAAM but also provides a framework for optimizing machining practices, enabling their effectiveness in industries demanding precision and durability.